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Injuries and Accident Causes in Fertilizer Manufacturing A Detailed Analysis of Hazards and Injury-Frequency Rates in 1946 by Region, Plant-Size, and Department Bulletin No. 949 UNITED STATES DEPARTMENT OF LABOR BUREAU OF LABOR STATISTICS Injuries and Accident Causes in Fertilizer Manufacturing Bulletin No. 949 UNITED STATES DEPARTMENT OF LABOR Maurice J. Tobin, Secretary BUREAU OF LABOR STATISTICS Ewan Clague, Commissioner For sale by the Superintendent of Documents, V. S. Government Printing Office, Washington 25, D. C. Price 20 cents Letter of Transmittal U nited States D epartment of Labor, B ureau of Labor Statistics, Washington, D. C., February 15, 1949, T he Secretary of Labor: I have the honor to transmit herewith a report on the occurrence and causes of work injuries in the fertilizer manufacturing industry based upon injuries reported during the year 1946. This report, a portion of which appeared in the December 1948 Monthly Labor Review, constitutes a part of the Bureau’s regular program of compiling work-injury information for use in accident-prevention work. The statistical analysis and the preparation of the report were performed in the Bureau’s Branch of Industrial Hazards by Frank S. McElrov and George R. McCormack. The specific accident-prevention suggestions were prepared by the engineering staff of the Safety Standards Division of the Bureau of Labor Standards. E wan Clague, Commissioner. Hon. Maurice J. T obin, Secretary of Labor. Contents The injury record----------------------------------------------------------------------------------------------------------------------------------Injury severity----------------------------------------------------------Injury rates by type of plant------------------------------------------------------------------------------------------------------------------Regional and State injury-frequencyrates__________________________________________________________________ Dry-mixing plants---------------------------------------------------------------------------------------------------------------------------Combination superphosphate anddry-mixing plants____________________________________________________ Integrated plants____________________________________________________________________________________ Injury rates and size of plant-----------------------------------------------------------------------------------------------------------------Plant safety activities--------------------- ----------------------------------------- --------------------------------------------------------First-aid facilities----------------------------------------------------------------------------------------------------------------------------------Departmental injury rates__________________________________________________________________________ Sulphuric-acid department__________________________________________________________ Superphosphate department______________________________________________________________________ Dry-mixing department-------------------------------------------------------------------------------------------------------------- — Maintenance department____________________________________________________________________________ Administrative and watchmen’sdepartments---------------------------------------------------------------------------------------Kinds of injuries experienced------------------------------------------------------------------------------------------------------------------Agencies involved in accidents----------------------------------------------------------------------------------------------------------------Types of accidents---------------------------------------------------------------------------------------------------------Accident causes--------------------------------------------------------------------Unsafe working conditions___________________________________________________________________________ Defective agencies____ ______________________________________________________________ Hazardous arrangements or procedures___________________________________________________________ Inadequately guarded agencies______________________________________________________________ Lack of personal protective equipment____________________________________________________________ Unsafe acts---------------------------------------------------Using unsafe equipment orequipment unsafely------------------------------------------------------------------------------Assuming unsafe positions or postures____________________________________________________________ Other unsafe acts---------------------------------------- (ii) Page 1 2< 2 3 3 4 4 4 4 5 6 6 6 7 8 8 8 9 10 11 11 12 12 13 13 14 14 14 15 Ill Typical accidents and suggestions for their prevention______________________________________________________ Receiving department accidents______________________________________________________________________ Superphosphate department accidents_________________________________________________________________ Dry-mixing and shipping department accidents________________________________________________________ Maintenance department accidents___________________________________________________________________ Miscellaneous accidents______________________________________________________________________________ Appendix.—Statistical tables: Table 1. Industrial injury rates for 521 fertilizer establishments classified by kind of plant and by extent of disability, 1946___________________________________________________________-________________________ Table 2. Industrial injury rates for 521 fertilizer establishments classified by geographic area, State, kind of plant, and extent of disability, 1946_________________________________________________________________ Table 3. Industrial injury rates for 521 fertilizer establishments classified by size of plant and by extent of disability, 1946--------------------------------------------------------------------Table 4. Industrial injury rates for 521 fertilizer establishments classified by type of safety program and by extent of disability, 1946___________________________________________________________________________ Table 5. Industrial injury rates for 521 fertilizer establishments classified by department and by extent of disability, 1946____________________________________________________________________________________ Table 6. Plant rules relating to the use of personal protective equipment in 521 fertilizer manufacturing plants, 1946______________________________________________________________________________________ Table 7. Disabling and medical injuries in 185 fertilizer establishments classified by part of body injured and by extent of disability, 1946________________________________________________________________________ Table 8. Disabling and medical injuries in 185 fertilizer establishments classified by nature of injury and by extent of disability, 1946___________________________________________________________________________ Table 9. Disabling and medical injuries in 165 fertilizer establishments classified by nature of injury and by department, 1946_________________________________________________________________ _ _____________ Table 10. Disabling and medical injuries in 185 fertilizer establishments classified by part of body injured and by nature of injury, 1946____________________________ Table 11. Disabling and medical injuries in 165 fertilizer establishments classified by part of body injured and by department, 1946-------------------------------------------------------------------------------------------Table 12. Agencies involved in injury-producing accidents in 165 fertilizer plants classified by operating department, 1946__________________________________________________________________________________ Table 13. Types of accidents resulting in injuries in 165 fertilizer plants classified by operating department, 1946________________ Table 14. Agencies and unsafe working conditions involved in injury-producing accidents in 153 fertilizer plants, 1946______________________________________________________________________________________ Table 15. Unsafe working conditions involved in injury-producing accidents in 148 fertilizer plants classified by operating department, 1946_____________ Table 16. Unsafe acts involved in injury-producing accidents in 160 fertilizer plants classified by operating department_______________________________________________________________________________________ Charts Chart 1. Part of body affected by disabling and medical injuries in the fertilizer manufacturing industry, 1946__ Chart 2. Major types of accidents in the fertilizer manufacturing industry, 1946______________________________ Chart 3. Major agencies involved in accidents in the fertilizer manufacturing industry, 1946___________________ . Chart 4. Major types of unsafe working conditions in the fertilizer manufacturing industry, 1946--------------------Chart‘5. Major types of unsafe acts in the fertilizer manufacturing industry, 1946____________________________ Page 15 16 17 18 21 22 23 23 25 25 26 26 27 27 28 28 29 29 30 31 32 32 iv 10 12 13 14 IV Chart 1.— Part of Body Affected b y Disabling and M ed ical Injuries in the Fertilizer Manufacturing Industry, 1946 18%- Foot or Toes 2% -Other UNITED STATES DEPARTMENT OF LABOR BUREAU OF LABOR STATISTICS Injuries and Accident Causes in Fertilizer Manufacturing The Injury Record1 A disabling work injury for every 14 employees, the highest injury-frequency rate in the chemical manufacturing group of industries, and one of the highest injury-severity rates in the entire list of manufacturing industries—this was the workinjury record of the fertilizer manufacturing industry for the year 1946.2 Although the 1946 injury-frequency rate for fertilizer manufacturing—35.7—represented the peak of an upward trend which had its beginning in 1940, high injury rates are not unusual in this industry. In the prewar years 1938 and 1939, the frequency rate for fertilizer manufacturing was about 26; for all chemical manufacturing in dustries it was about 10, and for all manufactur ing about 15. Wartime influences, which began to be effective in 1940, pushed the frequency ratres for most industries to higher levels, reconversion problems helped to hold them at those high levels through 1946. In 1946 the rate for the fertilizer industry, as above stated, was 35.7;3 the average rate for the chemical group of manufacturing industries was 15.7 and the all-manufacturing rate was 19.9. A significant feature of these rates is that their rela-* i This study was based upon summary reports from 521 fertilizer plants, which in 1946 employed 27,460 workers, representing approximately 83 per cent of the estimated total employment in the industry. The reporting group included 336 dry-mixing plants, 78 integrated plants combining acid and superphosphate production with dry-mixing, 57 plants combining super phosphate production with dry-mixing, 18 plants producing only super phosphate, and 32 plants which did not indicate their specific operations. *A disabling injury is one which results in death or permanent physical impairment, or renders the injured person unable to work at any regularly established job, which is open and available to him, throughout the hours corresponding to his regular shift on any day after the day of injury. The injury-frequency rate is the average number of disabling work injuries for each million employee-hours worked. The severity rate is the average number of days lost or charged for each 1,000 employee-hours worked. The standard time-loss ratings for fatalities and permanent disabilities are given in the American Standard Method of Compiling Industrial Injury Bates, approved by the American Standards Association, 1945. *In 1947 these rates moved down to 31.6 for fertilizer manufacturing, 12.6 for the chemical group, and 18.8 for all manufacturing. ( 1) tion to each other was nearly the same as in 1938 and 1939. A high degree of hazard is admittedly present in fertilizer manufacturing. But this is also true in many other industries which have achieved far better injury records through strict attention to basic safety principles. In 1946 the explosives industry had an injury-frequency rate of 5.7; iron and steel a rate of 9.5; cement, 11.0; motor-ve hicles, 10.8; and shipbuilding, 20.7. Even among the woodworking industries, which are generally listed at the top of all hazardous operations, planing mills had a slightly better rate (35.1) than fertilizer manufacturing in 1946. Only 14 of the 151 manufacturing industries for which 1946 rates were available had rates higher than the fertilizer rate. The available information indicates that about 2,360 employees in fertilizer manufacturing were disabled by work injuries in 1946. About 20 died as a result of their injuries, and about 60 were left with some form of permanent physical impair ment. The other 2,280 were more fortunate in that their disabilities were temporary in nature, leaving no adverse effects to restrict their working ability. Immeasurable humanitarian and social impli cations are presented by these injuries. From the economic viewpoint alone, however, they rep resent a very large expense item which the in dustry must absorb. Actual time lost by fertilizer workers because of work injuries experienced in 1946 is estimated at about 48,000 man-days. On the basis of average weekly earnings of $32.92 for production workers in the industry during that year, this would represent a direct loss of $225,000 in wages alone. Time lost within the year, however, does not adequately measure the real loss resulting from the injuries. Many of the seriously injured work- 2 ers will find that their earning ability is reduced for the remainder of their lives. With regard to those who were killed, the loss is equivalent to their entire expected earnings during the years in which they would have continued to work if their careers had not been cut short. If additional allowance is made for the future effects of the deaths and permanent impairments included in the total, the economic time loss chargeable to the injuries experienced in 1946 would amount to about 234,000 man-days. Evaluated on the basis of 1946 earning levels, this would represent a loss of $1,100,000 in present and future earnings, all of which must be absorbed by the employers, the workers, their dependents, and the consumers. Wage losses, however, represent only part of the total cost of accidents which produce work in juries. In addition there are payments for medical and hospital care and many indirect costs such as damage to materials or equipment, lost pro duction, and supervisory time spent in caring for the injured or reorganizing operations after the accident. The indirect costs are seldom a matter of record, but this does not lessen their reality. Studies have indicated4 that for manu facturing generally, indirect costs of injury-pro ducing accidents average about four times the direct cost of compensation payments plus hospital and medical expense. Assuming that this ratio is approximately correct for the fertilizer industry, it may be estimated, conservatively, that the indirect costs associated with injuries in that industry during 1946 amounted to at least 3.3 million dollars and that the total cost probably was over 4.4 million dollars. Injury Severity In general, the injuries experienced by fertilizer workers tended to be more severe than those re ported in most other manufacturing industries. The proportion of all disabling injuries resulting in death or permanent-total disability (0.9 percent) was three times as high as for all-manufacturing. Permanent-partial disabilities, on the other hand, constituted only 2.5 percent of the fertilizer indus try cases as compared with 4.9 percent for all manufacturing. The average time charge for each permanent-partial disability in the fertilizer indus 4 See Industrial Accident Prevention, by H. W. Heinrich, New York, McGraw-Hill Book Co., 1941. try, however, was 1,165 days in contrast to an average of 938 days for all-manufacturing.* In respect to temporary-total disabilities, the com parison was more favorable. In the fertilizer industry these cases had an average time loss of 15 days, while the all-manufacturing average was 17 days. Reflecting the high ratio of death and perma nent-total disability cases and the high average time charge for permanent-partial disabilities, the average time charge for all disabling injuries in the fertilizer industry was 99 days per case. The corresponding average for all-manufacturing was 82 days per case. Similarly, the standard severity rate for fertilizer manufacturing (3.5) was sub stantially higher than the all-manufacturing rate ( 1.6 ). Injury Rates by Type of Plant The manufacture of commercial fertilizer con sists of three distinct operations—the manufacture of sulphuric or phosphoric acid, the manufacture of superphosphate, the mixing of the fertilizer materials into the finished product. Although some of the larger plants perform all of these operations, most plants in the industry purchase the acid and superphosphate and perform only the mixing operations on their own premises. A few plants combine the manufacture of superphosphate with dry-mixing and a few others manufacture only superphosphate for sale to the exclusively dry-mixing plants. As the inherent hazards of these three operations differ substantially, the injury records for the different types of plants showed marked variations. Injuries were most common in the integrated plants which perform all three operations. For this group the injury-frequency rate was 40.7. The plants manufacturing only superphosphate had a rate of 40, while those combining the manufacture of superphosphate with dry-mixing had a rate of 37.4. The lowest average, 31.9, was for the ex clusively dry-mixing plants. On the basis of these rates it appears that the greatest injury probabil ities lie in the manufacture of superphosphate. In respect to the severity of the injuries, how ever, the record was different. Although super phosphate workers were injured more frequently, their injuries generally were less severe than those experienced by workers engaged in dry-mixing 3 operations. The plants manufacturing super phosphate alone had a very low ratio of serious disabilities which gave them a low average time charge per disabling injury (19 days) and a cor respondingly low severity rate (0.7). The fully integrated plants, with a higher ratio of serious injuries, had an average time charge of 58 days and a severity rate of 2.4. The exclusively dry mixing plants had an average time charge of 108 days and a severity rate of 3.4 while the combina tion superphosphate and dry-mixing plants had an average time charge of 121 days and a severity rate of 4.5. Regional and State Injury-Frequency Rates Many factors contribute to the wide differences in the injury-frequency rates prevailing in the various States and regions, and in particular instances it may be difficult to specify which is the controlling factor. Variations in the types of operations carried on by the reporting establish ments may have a direct bearing upon the level of frequency rates when the number of reporting units is small. When the groups to be compared are reasonably large and the comparisons are limited to establishments engaged in similar activities, however, the differences in the average injury-frequency rates may be considered as re flecting primarily variations in safety activities rather than variations in inherent hazards. Differences in State safety requirements and in the degree to which the requirements are enforced exert a direct influence upon the frequency-rate levels in different States. Similarly, safety activi ties, or the lack of such activities on the part of trade associations, local safety councils, or other organizations may have considerable effect upon the accident record of an area. The average size of the plants in different areas and the availability or the lack of experienced personnel are also factors which may influence the injury-frequency rate levels. The plants participating in the survey were distributed among 37 States, but 288 of the 521 reporting plants were located in the South Atlantic region and 56 others were in the East South Central region. As a result the coverage in many States and in some regions was insufficient to per mit the computation of representative averages for the various types of operations. For purposes of general comparison the reports were combined into regional groups corresponding to the nine regions used in the tabulations of the United States Bureau of the Census.5 On this basis average frequency rates for exclusively dry-mixing plants were computed for four regions; averages for plants combining superphosphate production with dry mixing were computed for three regions; and aver ages based upon the experience of completely integrated plants were computed for five regions. In addition it was possible to compute separate State averages covering the operations of dry mixing plants in seven States and for integrated plants in eight States. Only three State averages could be computed for plants combining super phosphate and dry-mixing operations. DRY-MIXING PLANTS The highest of the four regional frequency-rate averages for dry-mixing plants was 40.2 for the 29 plants reporting from the East South Central region. No State averages could be computed in this area. The lowest of the regional averages was 26.7 for the 195 plants reporting from the South Atlantic region. With this volume of reports it was possible to compute separate averages for six of the eight States comprising the area. Georgia’s average of 17.8, covering the experience of 48 plants, was the lowest in the region. The highest, 35.9, for 28 plants in Florida, was only slightly above the national average of 31.9 for all drymixing plants. In Maryland, 16 plants had an average of 27.5; in Virginia 21 plants had an average of 26.2; in South Carolina 36 plants had an average of 24.8; and in North Carolina 40 plants had an average rate of 22.2. In the Pacific region the 22 reporting establish ments had an average rate of 38.8. Seventeen of these plants, with an average rate of 36.2, were located in California. Nineteen dry-mixing plants reported from the 8 The regional groupings and the States included in each region are as fol lows: New England.—Connecticut, Maine, Massachusetts, New Hamp shire, Rhode Island, and Vermont. Middle Atlantic.—New Jersey, New York, and Pennsylvania. East North Central.—Illinois, Indiana, Michigan, Ohio, and Wisconsin. West North Central.—Iowa, Kansas, Minnesota, Missouri, Nebraska, North Dakota, and South Dakota. South Atlantic.— Delaware, Florida, Georgia, Maryland, North Carolina, South Carolina, Virginia, and West Virginia. East South Central.—Alabama, Kentucky, Mississippi, and Tennessee. West South Central.—Arkansas, Louisiana, Oklahoma, and Texas. Mountain.—Arizona, Colorado, Idaho, Montana, Nevada, New Mexico, Utah, and Wyoming. Pacific.—California, Oregon, and Washington. 4 most common findings have been that the small plants in which the owners are in close contact with actual operations and the large plants, which commonly have safety-engineers on their pay rolls, COMBINATION SUPERPHOSPHATE AND DRY-MIXING usually have the lowest average frequency rates. PLANTS The medium-size plants, which are too large for In the East South Central region 12 plants, intimate supervision by top management and too which combined production of superphosphate small to have regularly established safety depart with dry mixing, had an average frequency rate ments commonly constitute the group which has of 43.4. In the East North Central region 12 the highest average frequency rate. Small plants predominate in the fertilizer in plants had an average of 32.4 and in the South Atlantic region 23 plants had an average of 26.9. dustry. Of the 521 reporting establishments, 226 Each of these was well below the national average employed fewer than 25 workers apiece. Only 67 of 37.4. State averages could be computed only plants reported as many as 100 employees and for Georgia, 33.1; for Ohio, 25.9; and for Tennes only 11 of these reported that they employed 250 or more workers. Nevertheless, the frequency see, 49.8. rates in this industry closely followed the pattern INTEGRATED PLANTS observed in other industries. The 5 regional average injury-frequency rates The plants employing 25 to 49 workers had the for fully integrated plants ranged from a high of lowest average frequency rate, (30.5), followed by 53.3 for 3 plants in the Middle Atlantic region to the large plants each of which employed over 250 a low of 28.4 for 9 plants in the East South Central workers, with an average rate of 32.7. The very region. No State averages could be computed in small plants, each employing fewer than 25 either of these regions. workers, had an average rate of 33.9. These were In the South Atlantic region the average rate all lower than the over-all average of 35.7. The for 46 integrated plants was 41.4—slightly above highest averages were for the two groups of the national average of 40.7. Among the 6 State medium-size plants, 37.0 for plants with 50 to 99 averages computed in this region the Florida rate employees and 39.2 for plants with 100 to 249 of 51.5 based on the experience of 4 plants was employees. high and the North Carolina rate of 29.2 based on In respect to the severity of the reported in 9 plants was low. Each of the other rates for juries, however, the picture was different. The States in this region was above the national large plants employees and over) had the average. The Georgia average for 14 plants was highest injury(250 severity 6.3, and the highest 41.9; the Maryland average for 4 plants was 42.1; average time charge perrate,disabling injury (193 the Virginia average for 7 plants was 42.5; and the days). The lowest severity rate, 2.0, and the South Carolina average for 8 plants was 44.0. lowest average time charge, 50 days, was for Four integrated plants in the West South plants in the 100 to 249 employee group. The Central region had an average frequency rate of very small plants (under 25 employees) made a 33.0. Three of these plants in Louisiana had an relatively good showing in this comparison with a average rate of 39.2. severity rate of 2.4 and an average time charge of In the East North Central region the 12 report 70 days. Plants reporting 25 to 49 employees, ing plants had an average rate of 34.3. The Ohio however, had a high severity rate, 3.9, and a high average based on the experience of 7 of these average time charge, 128 days. plants was 40.7. Plant Safety Activities Injury Rates and Size of Plant Relatively few plants in the fertilizer industry Previous studies in other industries have in have developed formal safety programs. Only dicated that there is generally a direct correlation 14 of the 521 establishments reporting in the sur between injury-frequency rates and the size of vey indicated that they employed full-time safety the plants as measured by employment. The engineers and only 169 reported that they had East North Central region. These plants had an average frequency rate of 30.8. No State averages could be computed for this area. 5 organized safety committees. Although it is probably inaccurate to ascribe all of the difference to the fact that they employed a full-time safety engineer, the record does show that the plants which had safety engineers achieved a far better average injury record than that of the plants which had no safety expert on their pay rolls. The 14 plants with safety engineers had an average frequency rate of 17.4, while those which did not have safety engineers had an average rate of 36.0. The most pro nounced difference was in the volume of tem porary-total disabilities, but it was also apparent that the plants with safety engineers had a somewhat lower rate for fatalities and permanentimpairment cases. The value of safety committees could not be clearly demonstrated from the available data, primarily because there was no information re garding the relative activity or inactivity of the respective committees. The data indicated, how ever, that among the plants which had safety committees better results were achieved when both supervisors and nonsupervisory employees par ticipated than when committee membership was limited to supervisory personnel. Twelve of the 14 plants having safety engineers also reported that they had safety committees. These 12 plants had an average frequency rate of 17.3, which did not differ significantly from the 17.4 average for all 14 plants with safety engineers. Among the 12, however, there were 8 plants which included only supervisors in their committees. These plants had an average rate of 27.7 in contrast to the average of 12.9 for the 4 plants which included both supervisors and nonsupervisors in their committees. In the group of plants which did not employ safety engineers 157 reported that they did have safety committees. For some reason, however, the average frequency rate for these plants, 38.0, was considerably higher than the average for those which did not have committees (33.5). The plants having safety committees composed only of supervisors had an average rate of 40.0, while those which included both supervisory and non supervisory employees on their committees had an average of 35.9. Many of the cooperating plants reported that they furnished or required the use of personal protective equipment, such as goggles, respira824528°—49-----2 tors, gloves, or safety shoes in certain hazardous operations. These requirements, however, were far from uniform, and the accident record indi cated further that the rules were frequently dis regarded with unfortunate results. Slightly over half of the plants reported that they required the use of goggles in at least one operation or department. Most commonly this requirement applied to workers in the sulphuricacid, dry-mixing, and maintenance departments. A few plants required face shields instead of goggles. Nearly half of the plants required workers in their sulphuric-acid and/or dry-mixing departments to use respirators, and a few required gas masks for some operations in their sulphuricacid departments. About one-fifth of the plants required the use of gloves in certain operations. Only 14 plants reported any requirements re garding the use of safety shoes. Of the entire group of 521 plants, 330 reported that they had some requirements regarding the use of personal protective equipment and 191 reported that they had no rules whatever on this subject. First-Aid Facilities Although the provision of adequate first-aid facilities is not an accident-prevention measure, the presence of such facilities can do much to reduce the severity of the injuries which occur and may prevent many minor injuries from becoming disabling. Of the 482 plants which reported upon their first-aid facilities, 259 indicated that they had established regular first-aid rooms. However, only 7 of these first-aid rooms were staffed with professional attendants. Of the 223 plants with out first-aid rooms, 152 provided first-aid kits and 71 made no provision at all for first-aid treatment on the premises. Because of the wide variations in other factors which have a more direct bearing on the occur rence of accidents, frequency-rate comparisons have little significance in indicating the value of first-aid programs. Generally, those plants with better than average first-aid facilities also had better than average safety programs. It is of interest, however, that the plants with first-aid rooms had an average frequency rate of 33.7 while those without first-aid rooms had an average of 34.4. The 7 plants which provided professional 6 attendants in their first-aid rooms had an average frequency rate of 14.3. In a more restricted com parison limited to plants which employ safety engineers in addition to maintaining first-aid rooms, those which staffed their first-aid rooms with physicians or registered nurses had an aver age rate of 8.5, while those employing nonprofes sional attendants in their first-aid rooms had an average of 38.4. In conjunction with their first-aid programs, 23 plants reported that they required pre-employ ment physical examinations of all new employees to guide them in making work assignments. These plants, employing a total of 3,400 workers, had a combined injury frequency rate of 29.6, about 13 percent lower than the average rate for plants which did not require pre-employment physical examinations. Departmental Injury Rates Commercial fertilizer consists primarily of nitro gen, phosphate, and potassium mixed in varying quantities. Most plants purchase their potash and nitrogen requirements. Many also purchase the phosphate and confine their operations to mixing the ingredients according to their special formulas. Fully integrated plants, on the other hand, manufacture sulphuric acid and use it in the production of superphosphate, which they use in mixing the commercial fertilizer. The extent to which details were available con cerning the experience of workers engaged in particular operations varied greatly among the reporting plants. In many of the small plants, particularly those which specialize in one of the general types of operations, there was very little formal departmentalization. Most of the plants, however, were able to report their experience in broad categories of operations and many were able to furnish details for their service workers in three general divisions, administrative and clerical, maintenance, and watchmen. SULPHURIC-ACID DEPARTMENT The 44 sulphuric-acid departments for which separate reports were received had an average frequency rate of 38.4. In comparison with the records for most manufacturing activities this was a relatively high rate. It was, however, lower than the rates for the other major operating de partments of the fertilizer industry. None of the injuries reported in the sulphuric-acid departments resulted in death or permanent disability. As a result, the record showed a lower average injury severity for these departments than for any of the other operating divisions. It should be noted, however, that this average is based upon only 42 injury cases and may not be truly representative. In most of the sulphuric-acid departments, gases from the combustion of sulphur are mixed with steam, water, and other chemicals to form sul phuric acid. This is primarily a chemical reac tion and relatively few employees are needed. Generally, the sulphur is shoveled into a hopper from which it is fed automatically into the sul phur burner. The burner is a long, cylindrical, metal shell which is mechanically rotated to speed the burning of the sulphur. From the combus tion chamber the resulting gases are forced through a number of lead tanks where the water, steam, and other chemicals are introduced to combine with the gases and form sulphuric acid. The principal hazard of the department is the possibility of coming into contact with the acid itself. Workers necessarily must come close to the tanks in which the reaction takes place to read the tank gages, to test the strength of the acid at various stages, and to control the process. In these tasks they are frequently exposed to acid splashing from the tanks or dripping from leaks in the tanks and feed pipes. Access to the tanks is usually provided by erecting platforms near the bottom and at the top of each tank. Some of these platforms extend over the tanks. Falls from the platforms or from the ladders or steps leading to the platforms are common sources of injury. Hazards frequently encountered in the sulphur-burning operation in clude: exposure to fumes from the burners; un guarded gears by which the burner is rotated; overexertion in lifting or moving sulphur to the hopper; and the possibility of contact with the hot surfaces of the burner or with steam pipes. SUPERPHOSPHATE DEPARTMENT The average frequency rate for the superphos phate department (52.6), was higher than the rate for any other division of the industry. The injuries, however, tended to be less severe than 7 those experienced in most other departments. No deaths were included among the 144 disabling injuries reported and only 3 cases developed into permanent impairments. The severity rate (3.1) was high in comparison with the all-manufactur ing average (1.6), but was below the fertilizer industry average (3.5). Similarly, the average time charge per disabling injury (60 days) was well below the industry average (99 days). In this department sulphuric acid and finely ground phosphate rock are mixed together to form superphosphate, the bulk material of commercial fertilizer. Occasionally phosphoric acid is used in place of sulphuric acid and the resulting product is called concentrated superphosphate or triple phosphate. The phosphate, which usually comes to the plant in rock form, is first put through a rock grinder. From the grinder the pulverized phos phate is fed mechanically into a mixer where it is combined with dilute sulphuric acid. During the mixing, a chemical reaction takes place between the acid and the particles of phosphate. When the reaction has proceeded to a predetermined point the operator drops the semiliquid mixture, now called superphosphate, into a bin beneath the mixer. In this bin, known as the den, the chemical reaction continues and the superphosphate hard ens into a solid mass which must be broken up before it can be moved. Two methods of removing superphosphate from the den were observed in the course of the survey. In one of these methods a hydraulic ram and a set of revolving blades are mounted at opposite ends of the den. The ram forces the superphosphate against the blades which cut it into small pieces. The pieces fall onto a conveyor which carries them to storage bins for further aging. In the second method a scoop attached to cables and powered by an electric motor cuts into the pile and deposits the super phosphate on a conveyor or truck for transfer to the aging bin. The atmosphere in this department is usually very dusty, particularly in the vicinity of the rock grinder. Respirators and goggles, therefore, gen erally are considered essential equipment. Fine particles of rock dust and superphosphate settle on the floors and stairways, creating slipping hazards. In the den the floor is usually rough and uneven because of adhering superphosphate. Another hazard encountered in the den is the possibility of being struck by lumps of super phosphate falling or sliding from the piles. Contact with the acid in the superphosphate is a common source of burns not only in the den but throughout the department. Unguarded gears and belts on den machines, rock grinders, and conveyors are hazards found in many plants. Some plants use overhead industrial railways to transport the superphosphate to the storage or aging bins. Cars falling from these trackways present a serious hazard to the operators and to any other nearby workers. Workers near the aging bins are exposed to lumps of superphos phate falling from the piles in the bins and to traffic hazards created by the trucking opera tions necessary to move the material from the bins to the dry-mixing department. The super phosphate-mixer operator stands on the enclosed tank, in which dangerous fumes are constantly being generated. These fumes are exhausted mechanically, but any break-down in this system presents a serious hazard to the operator. DRY-MIXING DEPARTMENT The dry-mixing department had an average injury-frequency rate of 40.0 and an average severity rate of 3.6. A relatively high proportion of the injuries in this department resulted in serious disabilities—6 of the 879 disabling injuries were fatilities, 1 resulted in permanent-total disability, and 23 resulted in permanent-partial disability. As a result, the average time charge per disabling injury, 91 days per case, was higher than in any of the other major operating depart ments. In this department superphosphate and other dry ingredients are combined to make the com plete fertilizer. The mixing machine is generally placed near the roof of the building so that it may be emptied by gravity. Powered scoops, commonly called payloaders, deliver the materials to a point under the mixer. Here the ingredients are weighed and dumped into floor openings leading to a bucket conveyor which carries them up to the mixer. After the ingredients have been mixed sufficiently to assure homogeneity, the fertilizer is stored for further aging. When fully cured, the fertilizer is again conveyed to an elevated hopper which feeds through a screening mechanism to the bagging 8 machine. The operator of the bagging machine suspends an empty bag under the delivery nozzle of the machine, permits a sufficient quantity of the fertilizer to flow into the bag, closes the nozzle, and releases the filled bag from the machine. As it is released, the filled bag stands upright on a belt conveyor, which carries it to a sewing machine where it is closed and fastened. From the sewing machine the filled bags are taken to the warehouse for storage or are taken directly to railroad cars for shipping. The air of the mixing room is generally heavily laden with dust, most of which originates at the point where the dry ingredients are dumped into the hopper of the bucket conveyor. Generally the conveyor itself is enclosed, partly to guard against contact with its moving parts and partly to minimize the release of dust. Nevertheless, thick clouds of dust rise from the hopper as the materials are dumped in. A wide variety of hazards are created by this dust. Dermatitis and irritations of the eyes and respiratory passages frequently result from working in the dusty at mosphere. As the dust settles on floors and stair ways it creates a slipping hazard and when it accumulates in thick layers it frequently hardens to make the surfaces rough and uneven. These irregularities constitute tripping hazards and make it difficult to control the movements of the hand trucks and power trucks, which are exten sively used in this department. Poor visibility because of the dust in the air creates another hazard which 'is particularly dangerous in the vicinity of the floor openings leading to the bucket conveyors, into which workers might fall or into which they might run their trucks. Back strains and crushed fingers or toes resulting from the mishandling of heavy materials are com mon in the dry-mixing department. Many of these occur in handling bags of fertilizer, which gen erally weigh over 100 pounds, or in placing tempo rary gang-plates for hand trucking operations. Other hazards frequently encountered in this department include: unguarded moving parts on conveyors or sewing machines, and the “overhang” on piles of superphosphate, which develops during the removal of the material from the aging bins. A less common, but nevertheless serious hazard, arises from the occasional use of dynamite to loosen superphosphate which has hardened in the aging bins. MAINTENANCE DEPARTMENT Maintenance department workers had an injuryfrequency rate of 51.0, a severity rate of 3.0, and an average time charge of 58 days per disabling injury. On the basis of these averages, this department ranks among the most hazardous of the industry. By the very nature of their work, maintenance workers meet, on occasion, every hazard faced by any fertilizer worker, and in addition must contend with many which are seldom present in normal operations. As a result, maintenance workers sustain all kinds of injuries. Eye injuries and injuries to the hands and feet, however, are par ticularly common in this department, indicating that greater attention should be given to the use of goggles, gloves, and safety shoes. These work ers should also be thoroughly trained to recognize and cope with every plant hazard. ADMINISTRATIVE AND WATCHMEN'S DEPARTMENTS Administrative and clerical workers seldom encounter the many hazards of the operating departments. This was reflected in their relatively low injury-frequency rate, (2.8). It is note worthy, however, that 3 of the 12 injuries reported for these workers resulted in permanent disabili ties, a higher proportion than occurred in any other department. Watchmen, who generally enter the plant only during shut-down periods, also escape most of the operating hazards. However, they do en counter many of the hazards associated with poor housekeeping. In comparison with the rates of the operating departments their injury-frequency rate (8.3) was low, but it was substantially higher than the rate for the administrative and clerical department. Kinds of Injuries Experienced Inasmuch as the basic purpose of an accidentprevention program is to avoid the occurrence of events which result in injuries, analysis of the in juries which have occurred can serve a definite purpose in setting the stage for the more pertinent analysis of accident causes. It also performs a direct “injury prevention” function by indicating the possibilities of utilizing personal protective 9 equipment to supplement more specific accidentprevention methods. The most significant element in the general pattern of the reported injuries was the relatively high proportion of eye cases. Over 9 percent of all the disabling injuries and over 24 percent of the medical cases were eye injuries. About half of these were irritations, scratches, or bruises caused by dust or flying particles. The other half consisted primarily of chemical burns. Eye injuries were common in every operating depart ment, but were of outstanding importance in the maintenance, sulphuric-acid, and superphosphate departments. As the general use of goggles un doubtedly would have prevented all of these in juries, the need for an expanded eye-protection program in the industry is evident. About 18 percent of the disabling injuries and 26 percent of the medical cases were hand or finger injuries. The majority of these were cuts or bruises although there were a considerable num ber of sprains, fractures, and burns. Finger in juries were particularly common in the mainte nance department and hand injuries were par ticularly important in the superphosphate depart ment. Protective equipment which will prevent crushing injuries to hands and fingers is generally considered impracticable. Nevertheless, the use of proper gloves when handling chemicals or hot, rough, and sharp-edged materials, would probably have prevented most of the hand and finger burns and a large proportion of the cuts and lacerations. More than 23 percent of the disabling injuries and 13 percent of the medical cases were foot and toe injuries. The great majority of these injuries were bruises, cuts, or fractures resulting primarily from dropping heavy objects or from setting them down improperly. Many of these injuries prob ably would have been avoided if the workers had been wearing safety shoes or metal foot guards. Foot and toe injuries were particularly numerous in the dry-mixing department. Back injuries accounted for over 12 percent of the disabling cases and for over 6 percent of the medical cases. Most of these were strains or sprains resulting from lifting excessive weights or lifting improperly. Eleven percent of the disabling injuries and 7 percent of the medical cases were leg injuries. About half of the leg injuries were bruises. The remainder included a considerable number of cuts, strains, chemical burns, and scalds. Injuries to the head, other than eye cases, were relatively infrequent. Three of the 6 fatalities and 1 of the 2 permanent total disabilities reported in the survey, however, resulted from head in juries. Trunk injuries other than back cases accounted for 14 percent of the disabling cases and 10 per cent of the medical cases. These were predom inately bruises, but the total included a substantial number of strains, sprains, and hernias. The need for specialized safety programs for each of the major operating departments was strongly indicated by the differing patterns formed by the injuries in these departments. In the sul phuric-acid department 34 percent of all the reported injuries were chemical burns, 18 per cent were strains or sprains, and 16 percent were bruises. The most urgent need in this department therefore, is to develop safer methods of handling the acid to reduce this high proportion of chemical bums. In the superphosphate department 26 percent of the injuries were bruises or contusions, 23 per cent were chemical burns, 20 percent were cuts, and 14 percent were strains or sprains. Here the emphasis apparently should be placed first upon improving the methods of handling heavy mate rials and secondly upon avoiding contacts with acid. In the dry-mixing department 39 percent of the injuries were bruises or contusions, 20 percent were cuts, and 20 percent were strains or sprains. All of these types of injuries are associated with manual handling of heavy materials. Their pre vention calls for close study of the material handling methods now in use with the objective of revising those methods to reduce the hazards. In the maintenance department 27 percent of the injuries were bruises, 20 percent were cuts, 16 percent were foreign bodies in the eyes, and 14 percent were strains or sprains. The particular need for greater utilization of goggles is apparent in this department. Agencies Involved in Accidents Determination of the physical items or objects which are most frequently involved in accidents constitutes one of the fundamental steps in acci dent-prevention work. When these objects are 10 known it becomes possible to take steps to over come their accident-producing possibilities. To permit the precise determination of these items, which are commonly called “agencies,” the Amer ican Recommended Practice for Compiling Indus trial Accident Causes defines an agency as “the object or substance which is most closely asso ciated with the injury, and which in general could have been properly guarded or corrected.” Appli cation of this definition indicates that the agencies most commonly involved in accidents in the fer tilizer industry are vehicles, working surfaces, hand tools, chemicals, and machines. Vehicles were involved in approximately 20 percent of the accidents. Hand trucks were designated as the agencies in about half of these cases and tractors or payloaders were involved in about one-third. Other vehicles involved in fewer, but nevertheless substantial numbers of accidents, included railroad cars, motor trucks, and wheelbarrows. Vehicles were particularly important agencies of accident in the dry-mixing department where they were involved in over 29 percent of the accidents. In the superphosphate department nearly 14 percent of the accidents involved vehicles. Working surfaces were specified as the agencies in about 13 percent of the accidents. About half of these cases involved slippery, rough, or other wise defective floors. Defective surfaces on scaf folds, platforms, and ramps, however, were com mon. Defective working surfaces constituted a prominent source of accidents in all departments, but were particularly important in the dry-mixing department, where they were associated with the occurrence of over 14 percent of the accidents. Hand tools, constituting the third most promi nent group of agencies, were involved in 10 per cent of the accidents. The particular tools most commonly involved were bars, hammers, torches, and shovels. One in every five accidents in the maintenance department and one in every eight in the sulphuric-acid department wras a hand-tool accident. Although chemicals were designated as the agency in only 7 percent of the total volume of accidents in the industry, this group of agencies was of outstanding importance in the sulphuricacid and superphosphate departments. Chem icals constituted the agency in 16 percent of the superphosphate-department accidents and in 14 percent of the accidents in the sulphuric-acid department. Machines were directly associated with the occurrence of about 7 percent of all accidents in the industry. Nine percent of the accidents in the superphosphate department and 8 percent of those in the maintenance department were ma chine accidents. Other agencies of lesser prominence in the industry totals were nevertheless particularly important in the experience of individual depart ments. Defective boilers and tanks, for example, constituted the leading source of accidents in the sulphuric-acid department, where they were in volved in over 14 percent of the accidents. Flying particles which entered workers eyes were also important as accident agencies in this department as well as in the maintenance department. Types of Accidents The most common type of accident was that in which an employee was struck by a moving or falling object. This type of accident was respon sible for 37 percent of the injuries for which Chart 2.— M ajor Types ofAccidents in the Fertilizer Manufacturing Industry, 1946 PERCENT OF ALL INJURY-PRODUCING ACCIDENTS UNITED STATES DEPARTMENT OF LABOR BUREAU OF LABOR STATISTICS 11 details relating to the manner of their occurrence were available. The agencies most commonly involved in these accidents included vehicles, hand-tools, lumps of superphosphate or fertilizer, bags of materials, gang planks, lumber, and metal parts. The “struck by” type of accident was common in all departments but was of particular importance in the maintenance and dry-mixing departments. Accidents of this type produced 47 percent of the injuries in the maintenance department, 38 percent of those in the dry mixing department, and over 20 percent in those experienced by workers in the sulphuric-acid and superphosphate departments. The general group of accidents designated as inhalation, absorption, and ingestion accounted for 13 percent of the injuries. Most of these injuries were chemical burns resulting from the absorption of chemicals by the skin or eyes. In both the sulphuric-acid and superphosphate de partments this was the most common type of accident. Nearly 40 percent of all injuries in the sulphuric-acid department and 30 percent of the injuries in the superphosphate department resulted from the absorption of chemicals. Accidents in which the injured person bumped into or struck against objects or equipment pro duced 12 percent of the reported injuries. Most of these accidents involved contact with fixed objects, although accidents involving machines, conveyors, and other moving equipment were not uncommon. The “striking against” type of accident was relatively most important in the superphosphate, dry-mixing, and maintenance departments. Accidents in which employees were caught in, on, or between objects or equipment also accounted for about 12 percent of the injuries. Moving equipment, such as conveyors and hand trucks, was involved in many of these accidents, but there were also many cases of mashed fingers, which were caught between hand trucks and fixed ob jects during hand-trucking operations, between bags of fertilizer or other materials during piling operations, or between gangplanks and floors as the gangplanks were being placed in position. Approximately 14 percent of all injuries in the dry-mixing department and 11 percent of those in the superphosphate department were attributed to this type of accident. Overexertion, primarily in lifting bags of fer tilizer or other heavy objects, was responsible for 11 percent of the injuries. Accidents of this type were particularly common in the dry-mixing and sulphuric-acid departments. Falls accounted for about 10 percent of the injuries. For the industry as a whole, falls from one level to another were only slightly more numerous than falls on the same level. In the maintenance department, however, falls from elevations outnumbered falls on the level by 6 to 1, and in the sulphuric-acid department by 2 to 1. Accident Causes This analysis is based on the accident records of 185 of the fertilizer plants surveyed.6 Although the combined injury-frequency rate of 41.6 for this group was higher than the industry average, there was no reason to believe that the pattern of accidents in these plants was essentially different from that of the entire industry. In order to broaden the analysis and permit greater detail, this part of the survey was extended to include not only disabling injuries, but also all other injuries requiring treatment by physicians. These data, covering 2,532 injury cases, were then analyzed according to the American Recom mended Practice for Compiling Industrial Acci dent Causes, as approved by the American Stand ards Association. UNSAFE WORKING CONDITIONS The most direct, and usually the most produc tive, accident-prevention measures are those which eliminate unsafe working conditions. Ex tensive engineering and the expenditure of large sums of money may sometimes be necessary to control particular hazards. Most unsafe condi tions, however, can be controlled simply and easily through supervisory action. Unfortunately, the need for such action is frequently overlooked because the existing hazards have become so much a part of the work environment that neither workers nor supervisors recognize their influence in producing accidents. Hazards arising from poor housekeeping, from inadequate maintenance standards, or from operations which have grad 8 These plants employed nearly 15,000 workers daring 1946. Bureau representatives transcribed from the original accident records of these plants a complete account of each work accident experienced by their employees during 1946. 12 ually expanded from their original scope without a definite plan often fall into this category. hand-trucking operations in the dry-mixing de partments, were frequently slippery because of ex cessive wear—a sign of inadequate maintenance. In addition to being slippery, floors and other Chart 3.— M ajor Agencies Involved in Accidents in the Fertilizer Manufacturing Industry, 1946 working surfaces frequently were broken, cracked or irregular to such an extent as to present definite tripping hazards. These irregularities, moreover, frequently caused hand trucks to swerve and bump into nearby persons or objects, or to injure the operators. Hazards of this type are generally quite apparent, and their continued existence can be interpreted only as evidence of slack super vision and inadequate maintenance. Defective vehicles also constituted a prominent source of accidents. Some of these were railroad cars with rough or slippery floors or splintered doors. The great majority, however, were plant vehicles such as payloaders with defective lifting mechanisms, or hand trucks with rough or splint ered handles, loose wheels, or broken braces. Other defective agencies, which caused fewer but nevertheless substantial numbers of accidents, included worn or cracked hand tools, worn or strained hoisting equipment, and sharp-edged or worn parts on conveyors, machines, boilers, and tanks. Most of these defects should have been apparent to the supervisors in the normal course of operations and specifically should not have been overlooked if regular safety inspections were made. arrangements or procedures. The haz Basically, the existence of such hazards represents Hazardous ards included in this general group usually result supervisory failure and carries a strong implica from a failure to plan operations so that they may tion of inefficient operation. A very large pro be carried on safely, or from a failure to enforce portion of the accidents in fertilizer manufactur operating rules relating to safety. Accounting ing stem directly from such supervisory failures. for 36 percent of the analyzed accidents, this Defective agencies. The general need for more group of hazards ranked with defective agencies adequate inspection and immediate repair or re as an outstanding source of accidents in the placement of imperfect equipment, tools, and ma industry. Operations involving the handling of heavy or terials was strongly indicated by the fact that 36 percent of the analyzed accidents were directly bulky materials always present serious injury possibilities and require thorough planning and due to defective agencies. Slippery floors and slippery surfaces on plat supervision in order that accidents may be forms, scaffolds, and gangplanks were particularly avoided. Careful consideration should be given prominent sources of accidents. In many cases to determination of the maximum weight any the slippery surface was due to accumulations of individual will be expected to lift, and mechanical loose fertilizer or rockdust—an indication of poor equipment or sufficient additional help should be housekeeping. This condition was very common provided whenever the weight exceeds the deter in the superphosphate and dry-mixing depart mined limit. The many strains and sprains ments. Metal gangplanks, used extensively in reported as resulting from lifting excessive weights, 13 particularly in the dry-mixing and maintenance departments, indicate that the industry generally has not given sufficient attention to this phase of safety. Chart 4.— M ajor Types of Unsafe W orking Conditions in the Fertilizer Manufacturing Industry, 1946 Safe operation of plant vehicles and safe handling of inherently hazardous materials such as acids also require careful planning by the supervisory staff and strict enforcement of the established rules of procedure. Vehicles, par ticularly hand trucks and pay loaders, were involved in a considerable number of collision accidents which probably could have been avoided if designated lanes for vehicular traffic had been provided and traffic rules had been enforced. Traffic accidents were common in nearly all departments. However, the greatest volume of accidents ascribed to other types of unsafe pro cedures were in the sulphuric-acid and super phosphate departments. Many of the latter 824528°—49----3 mishaps involved a failure to provide the proper tools or equipment for the work at hand, which resulted in misuse of available equipment. Materials and equipment placed in irregular and unstable piles, stored materials which en croached upon aisles and workplaces, loose materials and equipment left in aisles and work places, and congestion of materials in small spaces were common among the poor housekeeping conditions which led to accidents. Loose super phosphate or fertilizer, lumber stock, and bags of fertilizer were the agencies most commonly involved in these accidents. Tripping accidents were very common. Inadequately guarded agencies. Inadequately guarded agencies were responsible for approxi mately 16 percent of the analyzed accidents. Gears, belts, or other moving parts of machines and conveyors were the principal accident sources in this group. Over 60 percent of the accidents involving machines and conveyors resulted from inadequate guarding. Scaffolds, platforms, and ramps without railings or toeboards, and unguarded openings in floors were relatively common causes of accidents. The record also indicated that many of the ladders used in fertilizer plants were not equipped with ladder safety-shoes, that hand tools such as knives frequently had no handle guards, and that elec trical equipment was often ungrounded. Lack oj personal protective equipment All plants reported that personal protective equipment was provided and that its use when necessary was required. The accident reports indicated, how ever, that observance of this requirement was inadequate. Nearly 11 percent of the accidents for which the cause was determined were found to have occurred because the prescribed safety equip ment was not used. Accidents in which workers experienced eye injuries because they were not wearing goggles or face shields while working with chemicals or in the very dusty areas of superphosphate or mixing departments were most common. In addition, a number of cases of respiratory irritations could have been prevented by the use of respirators, and many hand and toe injuries could have been avoided through the use of gloves or safety shoes. The sulphuric-acid and superphosphate depart- 14 ments were most remiss in use of protective equipment, but the dry-mixing and maintenance departments also had very unfavorable records. Chart 5.— M ajor Types of Unsafe A cts in the Ferti lizer Manufacturing Industry, 1946 > UNSAFE ACTS For the purpose of accident analysis, an unsafe act is defined as “a violation of a commonly ac cepted safe procedure.” 7 Literally, this means that no action may be designated as unsafe unless there is an alternative safe procedure, but it does not imply that the employee who committed the unsafe act must have known the alternative safe method. It is apparent from the analysis that many of the injured employees knew the safe methods but decided not to follow them. It is also evident that many other employees committed unsafe acts simply because they did not know the safe procedures. The elimination of unsafe acts, therefore, is a twofold problem: first, employees should be carefully instructed in the safe methods of performing their duties; and, second, an adequate number of well-trained, safety-minded supervisors should be provided to enforce safe practices. Four general groups of unsafe acts were out standing—using unsafe equipment or using equip ment unsafely; assuming unsafe positions or pos tures; operating or working at unsafe speeds; and failing to use personal safety equipment or to wear proper clothing. Using Unsafe Equipment or Equipment Unsafely. Unsafe use of equipment, or its use for purposes for which it was not intended, accounted for about 9 percent of the analyzed accidents. Generally, these acts involved misuse of hand tools—for instance, using crowbars or pinch bars as hammers. This type of unsafe act was particularly frequent in the maintenance departments, but was also responsible for a high proportion of accidents in sulphuric-acid and superphosphate departments. Gripping objects insecurely accounted for about 8 percent of the accidents. Many workmen, as a result of improper handling of lumber stock, hand tools, metal parts, bags of fertilizer, and similar articles, dropped these objects and in consequence suffered bruised or fractured feet, toes, hands, or fingers. Accidents caused by loose handling of materials or equipment were most common in the maintenance departments. 7 In American Recommended Practice for Compiling Industrial Accident Causes, approved by the American Standards Association, 1941. 5> 10i 15• Percent of All Disabling and Medical Injuries c 20 UNSAFE USE OF EQUIPMENT U sin g U n sa fe Equ ipm en t O r GRIPPING OBJECTS INSECURELY Equ ipm en t U n safely TAKING WRONG HOLO OF OBJECTS OTHER T a k in g An U n sa fe INATTENTION TO FOOTING P o s itio n Or P o stu re l if t in g INCORRECTLY OTHER O peratin g Or W o rk in g A t U n sa fe S p e e d s Failure To Use Personal S a fe ty Equ ipm en t O th e r UNITEO STATES DEPARTMENT OP LABOR BUREAU OF LABOR STATISTICS Taking the wrong hold of objects was the cause designated for accidents in which employees per mitted their fingers to be caught between objects which they were piling, or between gangplanks and floors while they were placing the gangplanks in position, or between the handles of hand trucks and fixed objects. This type of unsafe handling accounted for 7 percent of the accidents. Other specific unsafe acts in this group included pulling hand trucks instead of pushing them, using equipment known to be defective, and using hands instead of hand tools. Assuming unsafe positions or postures. Failure to obey one of the basic safety rules, “Watch your step,” was responsible for more accidents in the fertilizer industry than any other individual unsafe act. Over half of the accidents in the unsafe position or posture group, 19 percent of all accidents in the industry, and over 20 percent of all accidents attributed to unsafe acts in the superphosphate and dry-mixing departments were attributed to inattention to footing. Loose fertilizer or rock 15 dust, pieces of scrap lumber or metal, rough floors, and stairways were involved in many of these mishaps. Incorrect lifting was responsible for approxi mately 5 percent of all accidents resulting from unsafe acts. Most of these accidents occurred when workmen attempted to lift objects while they were in awkward or stooped positions. Al though it was sometimes very difficult to determine when objects were too heavy to be lifted by an individual employee, an attempt was made to exclude from the tabulation of unsafe acts all accidents which occurred because adequate assist ance had not been provided—as it appeared that these actually resulted from unsafe working con ditions rather than from unsafe acts. Numerous accidents occurred because employees exposed themselves to pieces of superphosphate or other material falling or sliding from piles. Acci dents of this type were most common in the super phosphate departments. Less common injuryproducing unsafe acts in this group included walking or standing under suspended loads; enter ing enclosures which were unsafe because of high temperatures, gases, or other exposures; riding vehicles in unsafe positions; exposure on vehicular rights-of-way; running; and jumping from ma chines, railroad* cars, ladders, or similar equip ment. Other Unsafe Acts. Operating or working at unsafe speeds caused about 12 percent of all acci dents in the industry, and over 18 percent of all accidents in the dry-mixing departments. Vehi cles, either hand or mechanically operated, were involved in a high proportion of these accidents. Failure to wear personal safety equipment which had been provided, or failure to wear adequate clothing, was responsible for about 11 percent of the accidents. In the sulphuric-acid, the super phosphate, and the maintenance departments, failure to wear provided personal safety equipment was an especially noteworthy cause. Most of the instances resulted from the failure of employees to wear available goggles, respirators, and similar equipment. Four percent of all accidents involving unsafe acts were the result of operating equipment with out authority, starting or stopping equipment without giving warning signals, or failure to shut off or block equipment which was not being used. Other unsafe acts which contributed to the oc currence of accidents were unsafe loading, placing, and mixing; working on moving or dangerous equipment; and fighting or quarreling. Typical Accidents—Suggestions for Prevention To illustrate the general types of accident problems encountered in the fertilizer-manufactur ing industry, a number of accidents were selected for individual consideration. These cases were drawn from the experience of 11 typical plants. In selecting the cases, an effort was made to exclude accidents arising from conditions peculiar to a particular plant and to include only accidents which could be duplicated in many plants through out the industry. A number of the safety-engineering staff of the Bureau of Labor Standards of the United States Department of Labor investigated each of the selected accidents at the point of occurrence. On the basis of that investigation, recommendations were prepared to indicate specific procedures which might be employed to prevent the occur rence of similar accidents. The intention was not to make all-inclusive recommendations nor to attempt to propound authoritative safety rules for the industry. On the contrary, the purpose was merely to indicate that there is a simple approach to the prevention of practically every type of accident. Many safety engineers no doubt would attack the problems involved in these accidents from a different angle and would achieve equally good results. The method of prevention, however, is of secondary importance so long as it achieves its purpose. It is, never theless, significant that the recommendations repeatedly stress the necessity for greater atten tion to training the workers in safe procedures and for closer supervision to insure that the safe pro cedures are followed. It is recognized, however, that because much of the work in this industry is seasonal the problems of training and of providing adequate supervisions are more difficult than in industries where production is constant and em ployment is more regular. The importance of proper attention to safety in the design and lay-out of plants and structures, and in the design and guarding of machinery and 16 equipment is indicated by the fact that many of the accidents described could have been elimina ted or minimized in the design stage. RECEIVING-DEPARTMENT ACCIDENTS 1. A laborer was working in a gondola car while it was being unloaded with a swinging grab bucket. When the bucket swung around, it crushed the worker between the bucket and the side of the car. Workers should not be 'permitted in a gondola car which is being unloaded with a swinging grab bucket unless some provision has been mode to control the bucket with a tagline. 2. A grab bucket was being used to remove ma terial from the hold of a ship. One of the men working in the hold was injured when he was struck by the bucket as it was being lowered. Close supervision and adequate job planning are necessary to prevent accidents of this type. Hatch tenders should never give signals to raise or lower buckets until all men are in the clear. Employees in the hold should remain out of the hatchway while buckets are being moved. Supervisors should be responsible for the strict enforcement of these rules. 3. A grab bucket was being used to unload a ship. An employee, working in the hold, was struck on the head by a piece of superphosphate which fell from the grab bucket. (a) Close supervision and adequate job planning are necessary to prevent accidents of this type. Hatch tenders should never give signals to move buckets until all men are in the clear. Employees in the hold should remain out of the hatchway while buckets are being moved. Supervisors should en force these rules strictly. (b) All employees working in the hold of a ship should be provided, and required to wear, safety hats. 4. An employee was unloading limestone from a gondola car. A piece of limestone fell from the top of the pile and struck him on the foot. (a) Close supervision and adequate job training are necessary to prevent accidents of this type. The loading face of piles should be broken down to an angle of approximately 45°. (b) Workers handling heavy materials should wear steel-toed safety shoes. 5. While he was unloading a boxcar of super phosphate with a tractor, an employee was over come by carbon-monoxide fumes. Investigation disclosed that only one door of the boxcar was open and the carburetor of the tractor was not adjusted properly. (a) Frequent inspections and proper maintenance of all equipment such as tractors are necessary to prevent accidents of this type. (b) Adequate ventilation must be maintained in all areas where tractors are being operated. To secure cross-ventilation within the boxcar, both doors should have been opened. 6. A laborer was moving a wheelbarrow load of phosphate rock from a boxcar to a platform. His wheelbarrow struck a broken board in the gang plank causing the handle of the wheelbarrow to strike him in the groin. Regular and frequent inspections with proper maintenance are necessary to prevent accidents of this type. Defective equipment should be removed from service until the necessary repairs have been made. 7. An employee was using a wrench to open a valve on a tank car. As he was applying pressure to the wrench, the valve opened suddenly and he fell 8 feet to the ground, seriously injuring his back. (a) Close supervision and adequate job instruc tion are necessary to prevent accidents of this type. Ordy employees thoroughly trained in the hazards of this operation should be permitted to work on tank cars. (b) A long-handled wrench should be used to provide greater leverage and, when necessary, two employees should be assigned to this work. (c) A platform ladder should be provided for this work. 8. Two men were unloading bags of scrap leather from a truck. One employee on the truck was throwing the bags of leather to the other on the platform. A third employee walked between the truck and the platform and was struck by one of the bags. Close supervision and adequate job planning are necessary to prevent accidents of this type. Passage ways and working areas in which materials are being thrown should be roped off. 9. A laborer was using a jackknife to open burlap bags containing scrap leather. The knife slipped and cut his left arm. The use of jackknives should not be permitted in industrial operations. Safely designed industrial knives with suitable holders should be provided. 17 SUPERPHOSPHATE DEPARTMENT ACCIDENTS 10. An employee, operating a land plaster mill, felt an electric shock. He jumped from the mill and turned his ankle. The mill was not grounded and an inspection disclosed a loose connection on a 220-volt line. (a) All electrical equipment should be properly grounded. (b) All equipment should be inspected frequently on a regular schedule. Defective equipment should be repaired immediately or removed from service until repairs have been made. 11. A laborer experienced an injury to his left shoulder and ear when a bell weighing approx imately 10 pounds fell on him. The bell was used as a signal to indicate the completion of a batch of superphosphate. Investigation disclosed that the metal supports to which the bell was fastened had corroded. (a) All equipment should be inspected frequently on a regular schedule. Defective equipment should be repaired immediately or removed from service until such repairs have been made. (b) Overhead equipment in this department should be fastened to acid-resistant material. 12. An employee was tending a wet-mix machine. While watching the mixing operation through a manhole, a particle of acid phosphate was blown from the machine and lodged in his eye. Inves tigation disclosed that there was no mechanical exhaust equipment on the mixer. (a) The wet-mix machine should be equipped with an exhaust fan and air duct to convey the fumes and gases to the outside of the plant. Fre quent and regular inspections with proper mainten ance are necessary to assure its effective operation. (b) Workmen engaged in this work should be provided, and required to wear, goggles. 13. While cleaning an elevator pit with a shovel, an employee struck his hands against a nail protruding from one of the bulkheads. All protruding nails, spikes, and bolts should be removed. 14. A laborer was directed to unload an acid tank car. After connecting a hose to the valve, he applied the pressure necessary to force the acid from the car. When the acid did not flow, the employee opened the line to ascertain if there was pressure in the line. As he did so, acid sprayed over his face and neck, resulting in serious in juries. Investigation disclosed that the hose was clogged. (a) Definite safe 'procedures should be developed for this operation and the men should be trained in their application. In this case the employee should not have opened the line until the pressure had been cut off and the air bled from the tank. (b) An inspection of the hose before it was used should have revealed the clogged condition. (c) Face and eye protection should be worn while working with acids. 15. The drag line of a Novell drag became tangled on the drum. An employee attempted to straighten the line while the drum was in motion. His finger was caught between the drum and the line and was amputated. No powered equipment should be repaired or ad justed while it is in operation. Supervisors should enforce this rule strictly. 16. The operator of a double-drum drag line disengaged the clutch and attempted to pull back the line by hand before the drums had completely stopped. His hand was pulled into the pinch point and crushed between the cable and drum. No adjustments or repairs should be made on any equipment while it is in motion. 17. An automatic switch on a rock-mill plow failed to operate, causing the machine to j erk. The sudden movement threw the operator against the plow. Investigation disclosed that the switch had been reported as defective and repairs had been requested, but that the repairs had not been made. The supervisor had authorized use of the machine despite its defective condition. Defective equipment should be removed from service until repairs have been made. 18. A plank in the floor of a catwalk shifted under the weight of a buggy, causing the buggy to tilt and fall from the catwalk onto a pile of superphosphate 20 feet below. The operator fell with the buggy and suffered a broken back. Investigation disclosed that the maintenance crew had replaced a worn plank in the catwalk, but had not fastened the new plank in place. (a) All repair work should be supervised and inspected by competent personnel before the repaired equipment is returned to service. (b) Catwalks should have standard railings. 19. An overhead tractor operator stood up as his tractor passed under the hoppers from which material was to be loaded into the cars which he 18 was pulling. His head struck one of the hoppers they were unable to stop because of the slippery and he was knocked from the tractor. The tractor condition of the floor due to dampness. (a) Where floors are likely to be wet, they should continued to a curve, where it left the tracks and be designed for good drainage, and should be surfaced fell to the floor below. (a) Hoppers should be designed so that tractor with a material having good antislip properties, even drivers passing under them will have adequate head when wet. (b) Mirrors should be placed at all ublind comers.” room. (b) Where headroom is low “tell-tails” of short In dusty places such as in dry-mixing departments, lengths of rope or light chains should be provided on these mirrors must be cleaned frequently. 23. A tractor operator was hauling fertilizer both sides of the obstruction to give warning. (c) Tractors should be equipped with udead man” from a stock pile to an elevator. When he made a sharp turn, the tractor turned over and fell on controls. (d) Guard rails or barriers should be provided at him, fracturing both his legs. (a) Trafficways should be designed and plainly all curves where the cars might jump the track at marked to eliminate sharp turns. operating speed. (b) All tractor operators should befully trained in 20. An overhead tractor operator was fatally injured when he and his tractor fell 30 feet onto the hazards of their operations. 24. As a tractor operator stepped down from a pile of phosphate rock. The operator had dumped a load of phosphate rock and had backed his machine he slipped on some wet superphosphate his tractor about 10 feet when the tractor jumped and fell against the tractor fracturing a rib. All working surfaces and passageways should the tracks. An investigation of the accident re vealed two possible causes of accident: (1) two frequently be cleaned of loose fertilizer, superphos tractor wheels were very loose, and (2) the operator phate, etc. 25. As a tractor operator uncoupled a fertilizer may have backed his tractor too fast for a curved car from his tractor, the tractor rolled back and portion of the track. (a) All equipment should be inspected frequently caught his thumb between the tractor and the car. on a regular schedule. Defective equipment should A flat-head coupling pin was being used. (a) All workmen should be thoroughly trained in be repaired immediately or removedfrom service until safe working procedures. Tractor operators should repairs have been made. be instructed lock the brakes on their machines (b) Curved portions of trackways should be de when they aretostanding idle and supervisors should signed for speeds at which the tractors will be used. rigidly enforce that rule. (c) Speed governors should be installed on all (b) A coupling-pin with a ring at the top for safe tractors. handling (d) Barrier guards should be erected along all head pin. should be substituted for the straight flatoverhead railways, especially at curves. 26. While pushing a fertilizer cart, a trucker pinched his hand between the handle of the cart DRY-MIXING AND SHIPPING DEPARTMENT ACCIDENTS and an upright beam. Knuckle or finger guards should be installed on 21. A payloader operator stepped from his the handles of fertilizer carts and hand trucks. vehicle to a trimming box which was used to hold 27. An employee who was pulling a loaded excess materials at the weighing platform. When the box tipped, the operator fell and bruised his Georgia buggy had his hand crushed between the handle and the wall when the buggy was deflected knee. striking a piece of hardened fertilizer lying in (a) Floor spaces should be kept free of loose objects by the passageway. such as tools, trimming boxes, scale weights, etc. (a) should push Georgia buggies (b) Trimming boxes should be anchored in insteadEmployees of pulling them. position. (b) Knuckle or finger guards should be attached 22. A jitterbug operator crashed into a second to the handles of all hand trucks. jitterbug as he turned a “blind corner.” Neither 28. A buggy operator pushed his buggy up vehicle was traveling over 5 miles an hour but behind a standing tractor. The tractor operator 19 Chains and sprockets should be completely en backed his machine without looking and crushed closed so that contact with them is impossible. the buggy operator between the buggy and a wall, 33. A dust particle entered the eye of an em (a) Tractor operators should he trained never to hack without first making sure that the path is clear. ployee while he was working at the elevator hole. (b) Hand truckers as well as tractor operators Goggles and dust masks had been provided for should maintain adequate clearance between trucks. this operation, but the worker was not wearing 29. An employee was adjusting the belt on a either. Generally this is one of the most dusty spots in a bagging machine while it was in operation. His hand was caught in the feeder belt lacing and was fertilizer plant. Goggles and respirators should be severely lacerated. The belt had been spliced with furnished and their use required in all work at this location. Supervisors should enforce this rule wire lacing. (a) No adjustments or repairs should be permitted strictly. 34. An employee was shoveling fertilizer into on any machine until the power has been shut off and the machine stopped. Supervisors should be an elevator hole when another employee drove a tractor in beside him and dropped the tractor required to enforce this rule strictly. (b) Leather lacing or spliced belting should be dipper on his foot. Investigation indicated that the shovelers in this location work very close to used instead of metal lacings. 30. A foreman of the bagging crew noticed that the tractors and that the tractor operators a belt had slipped from a pulley. He attempted generally depend upon the shovelers to move out to replace the belt on the pulley while the machine of the way of the dipper. Inasmuch as the motion of the dipper is controlled was in motion. In doing so, his hand was caught by the tractor operator, the responsibility for its safe in the pulley and severely crushed. (a) No adjustments or repairs should be permitted operation should be placed upon him. Operators on any machines until the power has been shut off should be trained to give warning before moving the dipper and should not move it until everyone is in and the machine stopped. (b) Regular and frequent inspection, with proper the clear. This rule should be enforced strictly. 35. A workman was directed to make an adjust repair of all defective equipment, is essential for ment on an overhead conveyor. As no ladder safety. In this instance the reason for the belt was available, he asked a payloader operator to running off the pulley should have been determined raise him to the conveyor in the payloader bucket. and corrected. As he was being raised, he steadied himself by 31. An employee was closing bags of fertilizer grasping the sides of the bucket. His fingers with a sewing machine which was suspended over were crushed between the edge of the bucket and a belt conveyor on which the bags were moving. one of the bucket supports. To protect his clothing, the operator was using (a) Proper ladders or platforms should be pro a burlap bag as an apron. The apron caught in vided for all work which is beyond reach from the the conveyor and the operator was thrown to floor and the use of makeshift supports should be the ground. (a) Workers should not be permitted to wear loose prohibited. (b) Equipment should never be used for any pur clothing around moving machinery. Supervisors pose other than that for which it was intended. This should strictly enforce this rule. (b) A barrier guard should be placed upon the rule should be enforced strictly. 36. A laborer was digging into a pile of ferti conveyor to eliminate the possibility of contact with lizer. undercut the pile and was struck by a moving parts when the sewing machine operator piece ofHesolidified material which fell from the reaches over the conveyor to operate the sewing overhang. machine. This is a very common accident in the fertilizer 32. A worker was removing bags of fertilizer industry. Careful instruction in safe procedures as they came off the end of a belt conveyor. As and close supervision are essential if these accidents he reached for a bag, his hand was caught and are to be avoided. Safe practice in breaking down crushed between the chain and sprocket at the end piled fertilizer requires that the working surface of of the conveyor. the pile be maintained at not over a 45° angle. 20 37. While sweeping around a milling machine, into the boxcar, one of the laborers sprained his an employee experienced a serious foot injury when ankle when his foot slipped from the gangway. The gangway was extremely slippery due to wet his foot was caught in an unguarded V belt. All V belts should be completely enclosed. fertilizer. Gangways, with nonslip surfaces, should be pro 38. A stock mill laborer was drilling a hole in a vided. Peanut-hull meal or other similar substances pile of superphosphate preparatory to placing a charge of dynamite. His supervisor had directed are frequently used to reduce the slipperiness of him to work on the side of the pile which was at gangways and floors. 44. A hand trucker was moving bags of fer an angle of approximately 45°. When his foot slipped, the electric drill penetrated his abdomen. tilizer from the mill to a boxcar. As he was push This accident was the direct result of poor super ing a loaded truck into the car, he collided with vision. A level working surface should have been an empty truck which was being returned from the car. As a result of the collision, the employee's provided before the workman began drilling. 39. A workman on the floor of the dry-mix de hand was caught between the side of the boxcar partment was struck on the head by a 3-inch grease and the handle of the truck. cup which fell from the catwalk of an overhead (a) Close supervision and adequate job planning conveyor. A repairman had left the cup lying are necessary to prevent accidents of this type. on the catwalk and the vibration of the conveyor Trafficways should be designed for safety and plainly had caused it to roll off. marked. Truckers should follow designated lines (a) All elevated working surfaces should be of travel to prevent collisions and should not attempt equipped with toe boards to prevent materials from to pass each other unless there is adequate clearance. sliding or rolling over the edge. (b) All truck handles should have knuckle guards. (b) All equipment should be carefully inspected 45. A buggy operator pushed his cart under a by competent personnel before being returned to oper tractor bucket which was being used to fill buggies ation after repair or adjustment. I f such an inspec with fertilizer. When the tractor bucket swung tion had been made, the discarded grease cup prob down, it fell across the cart, striking the right hand ably would have been seen and removed. of the operator. 40. A laborer was hand-trucking fertilizer on a Safe working procedures should be worked out for loading platform. Wlien one of the bags fell in this operation and employees thoroughly trained to front of his truck, the truck stopped suddenly and follow them. Supervisors should strictly enforce he walked into the handle. these procedures. Workmen should not be permitted Adequate job instruction and close supervision are to stand or work under suspended loads. necessary to prevent accidents of this type. Super 46. A laborer was pulling a Georgia buggy visors should make sure that all truck loads are uni loaded with raw material. One of the cart legs form and properly stacked. struck his foot, injuring his heel. 41. A hand trucker was wheeling bags of ferti Adequate job instruction and close supervision lizer into a boxcar. One of the wheels of his truck are necessary to prevent accidents of this type. struck a small piece of wood on the floor, causing Georgia buggies should be pushed, not pulled. the truck to tilt. He strained his back attempting 47. A laborer was taking 100-pound bags of to right the truck. fertilizer from a 10-foot pile. As he pulled one Good housekeeping is imperative to safety. Floors bag from the pile it dislodged a second bag which and all working surfaces should be kept free from fell on him. loose objects. (a) Piled bags should be interlocked by turning 42. A laborer was trucking bags of fertilizer the alternate rows. When the pile is higher than from a warehouse to the loading platform. When shoulder height, each row should be stepped back and his foot slipped on some wet fertilizer he fell and planks should be used to provide a stable working the loaded hand truck fell on him. surface on the steps. All working surfaces and passageways should be (b) Workers should not be required to move ma kept free from loose fertilizer, etc. terials to or from surfaces above shoulder height. 43. Several laborers were loading a boxcar dur 48. A worker was piling bags of fertilizer in a ing a rainstorm. While pushing a hand truck truck. As he placed the first bag for a new stack 21 he dislodged the adjacent stack which fell on him. defective flooring, the defective area should be bar This employee had not been given any instruction ricaded or covered with a warning standard. 53. A mechanic assisting in the installation of a as to the proper method of piling bags and at the time of the accident was working without super new overhead mixer dropped a wrench on the vision. head of a worker on the floor below. (a) Piles of bagged fertilizer should be interlocked The area directly below the mechanics should have by turning the alternate rows and each 'pile should been roped off. be given a slight taper. 54. An employee was using a sledge hammer to (b) Proper instructions should be given with each loosen a shaft from a bearing. While he was new assignment and the supervisor should train the engaged in this work, a small piece of steel flew worker for a long enough period to be sure that he is from the sledge and struck the workman’s face, cutting his lip. following the safe procedure. (a) A shaft and bearing puller should be used to 49. While attempting to open a boxcar door, a laborer was injured when his hand slipped from remove shafts from bearings. I f the puller is not the handle of the door and struck the side of the available, a soft-faced mallet should be used instead of a sledge hammer. car. (b) All hand tools should be inspected frequently Generally, boxcar doors are too heavy for an indi vidual to move. A group of men, thoroughly trained and regularly. Defective tools, such as hammers or to work as a team, should be assigned to this job, sledges with mushroomed or hardened heads, should be removed from service. or a mechanical door puller should be provided. (c) Goggles or face shields should be worn in work 50. A fork truck operator was seriously injured when his truck suddenly rolled back, pinning him of this nature. 55. A mechanic was using a wrench to tighten between the warehouse wall and the steering wheel. Investigation disclosed that the truck a coupling on a tank car. The wrench slipped and his fingers were crushed between the wrench had faulty brakes. (a) Equipment should be inspected frequently on handle and the car. Investigation disclosed that a regular schedule. Defective equipment should be the jaws of the wrench had been sprung so that repaired immediately or removed from service until it did not fit firmly on the nut. Tools should be inspected frequently and those repairs have been made. (b) A metal frame should be welded to the fork found to be defective should be replaced immediately. 56. A maintenance man burned his hand when truck behind the driver to protect him from being struck by other vehicles or moving equipment and he touched a weld which he had just completed. from being caught between his truck and other objects Gloves were provided for this operation, but he was not wearing them. Investigation revealed while he is backing. that this man had been given some training in MAINTENANCE DEPARTMENT ACCIDENTS welding, but was rarely called upon to perform 51. A mechanic was replacing a cagemill in a this kind of work. Supervisors should be familiar with the hazards hopper. While ‘lining up” the mill by hand, his foot slipped from the frame of the hopper and he involved in the work performed by their employees fell between the cage mill and the side of the and should see that all required precautions are hopper. taken. This is particularly important in respect to Proper staging should have been erected to assure operations which are unusual and with which the firm footing for mechanics engaged in this work. worker may not be entirelyfamiliar. In this instance 52. A maintenance man was called to repair the supervisor should have insisted upon the use of loose boards on the loading platform. The boards all the protective equipment provided for welding were not marked and in trying to locate them by operations. stamping on the platform he knocked one of them 57. A painter, working on a sloping roof with aside and suffered a fracture when his foot slipped out support, fell to the ground and fractured his leg. Work on sloping roofs should always be safe into the opening. Defective equipment should be marked and with guarded by such means as crawling-board stagings, drawn from service pending repair. In the case of guard ropes, or life lines. 22 58. A repairman attempted to raise an electric motor with a chain hoist. As it left the floor it swung against him, injuring his knee. Chain hoists should always be carefully spotted directly above the object to be lifted in order to min imize the possibility of the load swinging. In mak ing a heavy lifty a second person should control the swing of the load by means of a tag line. 59. A repairman was working under a tractor which was supported on a hydraulic jack. The jack suddenly released and allowed the tractor to settle, pinning him to the ground and crushing his chest. (a) Employees should not be permitted to work under equipment while it is supported by a jack. Solid blocking should be placed to take the weight after the equipment has been raised urlth the jack. (b) Regular equipment inspections probably would have revealed the defect in the hydraulic jack. 60. While a laborer was trying to remove a broken stem from an acid line valve, some acid splashed into his eyes. Employees working with or around acid should be furnished with and required to wear goggles. 61. A worker who was grinding a chisel had his hand pulled against the grinding wheel when the chisel caught on the wheel. Investigation dis closed that the distance between the tool-rest and the wheel was over one-half inch. The distance between the tool rest and the wheel should not be greater than % inch, so that tools cannot jam between them. Employees who use grinders should be thoroughly instructed as to their proper use and their procedures should be checked frequently to make sure they follow instructions. 62. A worker’s toe was fractured by an iron plate which fell from his workbench. The work bench was cluttered with tools and scrap metal. The plate had been resting on top of some of this material and slid off when he touched it. (a) Good housekeeping is essential to safety• Facilities for storing scrap material and for tools which are not in use should be provided and super visors should insist that all workmen make use of such facilities. (b) Workmen who handle heavy materials should wear steel-toed safety shoes. MISCELLANEOUS ACCIDENTS 63. A workman stood on a bagging machine to reach an overhead light. His foot slipped and he fell against the motor of the machine, bruising his hip. (a) All overhead lights should be controlled by switches placed in accessible locations. (b) The practice of climbing on equipment, tables, boxes, shelves, or other makeshift supports should be prohibited. When it is necessary to work at a point not accessible from the floor a suitable ladder should be used. 64. A laborer in the yard gang was pulling a wire cable from a boxcar winch in order to attach it to a nearby car. A broken wire in the cable lacerated his hand. He was not wearing gloves. All workers should be required to wear heavy gloves while handling wire cable. 65. A night watchman attempted to switch on a light at one of his stations. In order to reach the pull-cord, he stood on a hand truck. When the truck moved, the watchman fell, fracturing his hip. (a) All electric switches should be accessible from the floor. (b) Hand trucks should never be used as stepladders. 66. A yard laborer was moving a hydrogen cylinder. When he attempted to lift the cylinder, he sustained a hernia. All such workmen should be given general training in safe lifting and should be specifically instructed in the safe handling of heavy and awkward objects such as gas cylinders. Appendix: Statistical Tables T able 1.-^-Industrial injury rates for 521 fertilizer establishments, classified by kind of plant and by extent of disability, 1946 Number of disabling injuries Kind of plant1 Total.................................................... Superphosphate plants___________ Dry-mixing plants.............................. Superphosphate and dry-mixing plants.............................................. Integrated acid, superphosphate, and dry-mixing plants.................... Num ber of estab lish ments 521 18 336 57 78 Frequency rates of;i_ Severity Resulting in— Average number Em of days lost Num ployeehours Death Per Tem orpercharged ber of worked injury All and per manent- poraryem (in Death Per- Tem dis manent- partial total Severity ployees thou Total or per manentabling total dis dis Tem rate 4 manent- - partial porarytotal injuries dis abilities sands) total dis dis abilities poraryAll dis abilities abling total dis injuries dis ability 3 ability ability abilities 27,460 1,015 9,709 4,039 9,649 55,236 1,970 2,101 84 17,762 566 8,316 311 20,665 842 (3) 18 (1) 5 (1) 4 (1) 3 i Totals include figures not shown separately because of insufficient data. * Figures in parentheses indicate the number of permanent-total disability cases included. 50 1,902 1 83~ 19 542 8 299 17 822 35.7 40.0 31.9 37.4 40.7 0.3 .3 .5 .1 0.9 .5 1.1 1.0 .8 34.5 39.5 30.5 35.9 39.8 99 19 108 121 58 15 15 16 15 15 3.5 .7 3.4 4.5 2.4 2 The frequency rate is the average number of industrial injuries for each million employee-hours worked, 4 The severity rate is the average number of days lost for each thousand employee-hours worked. T able 2.— Industrial injury rates for 521 fertilizer establishments, classified by geographic area, State, kind of plant, and extent of disability, 1946 Number of disabling injuries Kind of plant by geographic area and State1 United States: Total____________ New „ Middle Atlantic: Total...................... Integrated acid, superphosphate, and dry-mixing plants_______ New Jersey: Total.............................. Pennsylvania: Total ____ ____ East North f!antral: Total ____ Dry-m ixing plants _ __ Superphosphate and dry-mixing plants Integrated acid, superphosphate, ftpfi dry-mixing plants Illinois* Total - __ __________ Indiana: Total .___________ Ohio* Total - __ Superphosphate and dry-mix ing plants _ ____ In te g ra te d acid, superphos phate, and dry-mixing Slants..................................... See footnotes at end of table. Num ber of estab lish ments Severity Resulting in— Average number Em of days lost Num ployeecharged hours Death Per Tem or ber of worked per injury and per All Death Per Tem dis manent- manent- poraryem (in Severity ployees thou Total or per manent- porary- abling total partial total manent- partial total injuries dis dis dis Tem rate 4 sands) abilities total dis dis abilities All dis poraryabilities dis abling total ability 2 ability ability injuries dis abilities 521 27,460 55,236 1,970 (3) 18 111 23 758~ 1,422 7 47 1,896 3,939 207 1 79 3 748 1,482 104 15 967 1,977 1 60 19 567 1,220 6 49 3,520 7,624 260 56 19 835 1,817 78 1,105 2,406 12 96 1,324 2,800 12 79 2,280 1,110 10 32 438 957 8 119 24 1,687 3,744 30 514 1,158 6 7 Frequency rates of; 765 1,645 67 (23) 50 1,902 3~ 108 198 2 78 2 54 254 55 75 94 78 31 115 28 35.7 78.0 52.5 53.3 52.6 49.2 34.1 30.8 32.4 34.3 34.6 33.4 31.8 25.9 1 66 40.7 2 6 1 3 2 1 1 4 101 0.3 99 48 232 90 98 619 43 1.7 34.5 75.9 50.2 52.6 51.1 44.3 33.3 30.2 31.2 33.6 34.2 32.4 30.7 24.2 37 85 14 15 13 14 13 14 13 16 .6 40.1 19 12 0.9 2.1 1.8 .7 .5 4.9 .5 1.0 .8 .6 1 .2 .7 .4 1.0 1.1 20 70 44 44 88 15 19 16 14 13 21 3.5 3.7 12.2 4.8 5.2 30.4 1.5 .6 2.3 1.5 1.5 3.0 1.2 2 .2 .8 24 T able 2.— Industrial injury rates for 521 fertilizer establishments, classified by geographic areat State, kind of plantt and extent of disability, 19J+6—Continued Number of disabling injuries Kind of plant by geographic area and State * South Atlantic: Total........................ Dry-mixing plants....................... Superphosphate and dry-mixing plants......................................... Integrated acid, superphosphate, and dry-mixing plants.............. Florida: Total..................................... Dry-mixing plants................. ...... Integrated acid, superphosphate, an d dry-m ixing plants...................................... Georgia: Total..................................... Dry-mixing plants____________ Superphosphate and dry-mixing plants.................................. Integrated acid, superphosphate, and dry-mixing plants........... Maryland: Total................................. Dry-mixing plants____________ Integrated acid, superphosphate, and dry-mixing plants.......... North Carolina: Total........................ Dry-mixing plants........................ Integrated acid, superphosphate, and dry-mixing plants_______ South Carolina: Total........................ Dry-mixing plants..... .................. Integrated acid, superphosphate, and dry-mixing plants................. Virginia: Total.................................... Dry-mixing plants........................ Integrated acid, superphos phate, and dry-mixing plants.. East South Central: Total................ Dry-mixing plants____________ Superphosphate and dry-mixing plants......................................... Integrated acid, superphosphate, and dry-mixing plants.............. Alabama: Total.................................. Tennessee: Total................................. Superphosphate and dry mixing plants......................................... West South Central: Total_______ Integrated acid, superphosphate, and dry-mixing plants_______ Louisiana* Total .. Integrated acid, superphosphate, and dry-mixing plants. Pacific: Total___ r . ___ Dry-mixing plants___________ California: Total __ Dry-mixing plants........................ Num ber of estab lish ments 288 195 23 46 38 28 Severity Resulting in— Average number Em of days lost Num ployeeor charged hours Death ber of worked Per Tem All and per manent- porary- per injury em (in Death Per Tem dis manentSeverity ployees thou Total or per manent- porary- abling total partial total manent- partial total injuries dis dis dis Tem rate * sands) total dis dis abilities poraryabilities All dis abilities dis abling total ability 2 ability ability injuries dis abilities 15,133 5,728 1,280 5,427 2,270 1,173 30,516 10,431 2,639 11,787 4,716 2,369 4 460 1,029 80 3,172 6,245 48 955 1,517 11 728 1,510 14 1,223 2,671 21 1,517 3,188 16 582 1,165 4 841 1,804 55 2,438 4,608 40 1,316 2,338 9 893 1,779 50 2,088 4,037 36 802 1,209 8 1,019 2,365 37 3,536 7,515 21 810 1,680 7 991 2,139 56 3,707 6,651 29 1,160 1,768 12 1,073 2,051 9 1,022 2,046 35 1,483 2,502 11 1,596 2,948 4 639 1,245 27 1,502 3,011 4 601 1,301 9 741 1,540 3 499 1,097 24 686 1,436 22 568 1,185 19 641 1,357 17 523 1,106 952 278 71 488 186 85 (3) 9 (1) 4 (1) 3 (1) 1 29 2 2 1 53 208 (1) 27 50 (1) 11 2 12 914 263 66 475 182 84 1 52 203 26 48 112 2 110 32 (1) 1 76 (1) 1 116 1 52 1 52 152 1 30 104 170 (1) 3 44 (1) 3 91 246 2 71 89 1 58 1 80 1 124 1 62 97 43 50 43 67 46 61 40 33 2 107 29 75 107 47 48 149 29 103 157 40 87 238 69 87 56 77 1 122 111 1Totals include figures not shown separately because of insufficient data. 2 Figures in parentheses indicate the number of permanent-total disability cases included. Frequency rates ofi 1 1 1 41 8 4 4 2 1 1 10 1 4 6 2 1 1 2 2 2 2 2 2 2 2 62 95 41 48 41 65 44 59 38 31.2 26.7 26.9 41.4 39.4 35.9 51.5 33.3 17.8 33.1 41.9 34.8 27.5 42.1 25.2 22.2 29.2 37.6 24.8 44.0 26.2 42.5 37.0 40.2 43.4 28.4 32.0 42.1 49.8 32.2 33.0 32.5 39.2 46.7 38.8 45.0 36.2 22.6 0.3 .4 1.0 1.1 1.1 .8 .1 1.0 .4 .4 .4 1.0 .2 .7 .3 .7 .7 .7 .9 .6 2.6 .6 .2 .4 1.7 1.7 2.2 .2 .5 .8 .4 .4 1.3 .3 1.9 .9 1.8 .5 .5 .4 .3 .6 1.1 .5 .5 .8 .3 .7 1.5 1.3 1.8 1.4 1.7 1.5 1.8 29.9 25.2 25.0 40.3 38.6 35.5 109 155 295 51 87 14 50.5 32.5 17.1 31.7 41.2 33.6 24.9 42 56 23 164 24 132 22 220 25 101 22 115 204 48 63 29 14 15 41.5 23.3 20.1 27.0 36.9 24.0 43.6 20.9 23.8 40.6 35.8 39.1 42.4 27.4 30.8 41.5 49.8 31.5 31.5 31.2 37.4 45.3 37.1 43.5 34.4 22 226 517 81 85 50 83 150 117 64 g 37 63 56 63 33 43 35 46 16 15 22 15 11 11 g 14 12 21 12 12 17 13 16 19 19 20 13 15 10 16 16 11 g 15 15 15 15 18 3.4 4.1 7.9 2.1 3.4 .5 2 .2 1.9 5.4 1.0 4.6 6 .0 4.2 2.9 4.5 1.4 2.4 #7 1 .0 5.1 13.5 3.5 3.1 2.0 3.6 4.2 3.7 2.7 .5 1.2 2.1 1.8 2 .5 21 1*7 18 1 6 21 1 .6 1.7 * The frequency rate is the average number of industrial injuries for each million employee-hours worked. * The severity rate is the average number of days lost for each thousand employee-hours worked. 25 T able 3.— Industrial injury rates for 521 fertilizer establishments, classified by size of plant and by extent of disability, 1945 Number of disabling injuries Size of plant Total.................................................... Less than 25 employees...................... 25 to 49 employees............................... 50 to 99 employees............................... 100 to 249 employees........................... 250 employees and over.................... Num ber of estab lish ments 521 226” 119 109 56 11 Frequency rates of*— Severity Resulting in— Average number Em of days lost Num ployeeor charged Death ber of hours Per Tem All and per manent- porary- per injury Death Per Tem dis em worked manentSeverity ployees (thou Total or per manent- porary- abling total partial total sands) manent- partial total injuries dis dis dis Tem rate * total dis dis poraryabilities abilities All dis abilities dis abling total ability i ability ability injuries dis abilities 27,460 3,006 4,248 7,490 7,907 4,809 55,236 1,970 (3) 18 4,922 T&T 249 8,171 15,602 577 (1) 35 16,673 654 (1) 1 9,868 323 (1) 8 - 1 Figures in parentheses indicate the number of permanent-total disability cases included. >The frequency rate is the average number of industrial injuries for each million employee-hours worked. 50 1,902 2 164 11 235 19 553 642 11 7 308 35.7 33.9 30.5 37.0 39.2 32.7 0.3 .4 .3 .2 .1 .8 0.9 .4 1.3 1.2 .7 .7 345 33.3 28.8 35.5 38.4 31.2 99. 70 128 99 50 193 15 15 16 16 14 17 3.5 2.4 3.9 3.7 2.0 6.3 *The severity rate is the average number of days lost for each thousand employee-hours worked. T able 4.— Industrial injury rates for 521 fertilizer establishments, classified by type of safety program and by extent of disability, 1946 Number of disabling injuries Type of safety program 1 Total.................................................... With full-time safety engineer........... With safety committee................ Of supervisory employees__ Ofpprvi<?nry supervisory and nonsup/mplnyees Without full-time safety engineer___ With safety committee................ Of supervisory employees— Of supervisory and nonsupervisory employees........... Without safety committee........... Num ber of estab lish ments Severity Resulting in— Average number Em of davs lost Num ployeech:arged Death Per Tem or ber of hours ljury and per All Death Per Tem dis manent- manent- porary- pern em worked Severity ployees (thou Total or per manent- porary- abling total partial total dis dis Tem rate 4 manentsands) partial injuries total dis total dis dis dis poraryabilities abilities abilities All dis abling total ability * ability ability injuries dis abilities 521 27,460 55,236 1,970 (3) 18 88 14 2,306 5,070 1 12 80 2,127 4624 1 1 615 1,374 8 38 42 4 1,512 3,250 472 21,907 43,796 1,576 (2) 12 914 (2) 8 157 11,545 24,040 47 3,589 7,647 307 (2) 4 491 4 79 6,717 13,679 655 (1) 4 310 10,251 19,548 i Totals include figures not shown separately because of insufficient data. 3 Figures in parentheses indicate the number of permanent-total disability cases included. Frequency rates of*— 50 1,902 4 83 4 75 37 4 38 44 1,520 24 882 295 8 13 474 20 631 35.7 17.4 17.3 27.7 12.9 36.0 38.0 40.0 35.9 33.5 0.3 0.9 .2 .2 .9 .3 .3 .5 .3 1.2 1.0 1.0 1.0 .7 .2 .8 1.0 1.0 34.5 16.4 16.2 27.0 11.7 34.7 36.7 38.5 34.6 32.3 99 168 182 171 192 92 94 127 90 91 15 17 15 14 16 16 16 18 15 17 3.5 2.9 3.1 4.7 2.5 3.3 3.6 5.1 3.2 3.0 a The frequency rate is the average number of industrial injuries for each million employee-hours worked. 4 The severity rate is the average number of days lost for each thousand employee-hours worked. 26 T a b l e 5 — Industrial injury rates for 521 fertilizer establishments, classified by department and by extent of disability, 1946 Number of disabling injuries Num ber of units report ing Department1 Total.................................................... Sulphuric-acid department................ Superphosphate department.............. Dry-mixing department..................... Administrative and clerical............... Maintenance Watehmen department................... Other departments............................. 8 521 44 79 388 285 147 128 83 27,460 456 1,224 11,482 2,094 1,108 319 952 55,236 1,970 (3) 18 42 1,093 144 2,739 21,978 879 0) 7 12 4,260 126 (1) 1 2,469 6 721 1,931 1 67 50 1,902 42 3 141 23 849 25 1219 5 1 66 ATjy type ..... Plants requiring use in certain operations Plants having no requirements Percent Number Percent of total Number of total 330 273 250 108 37 34 63.3 52.4 48.0 20.7 7.1 6.5 191 248 271 413 484 487 35.7 38.4 52.6 40.0 2.8 51.0 8.3 34.7 0.3 34.5 38.4 51.5 38.7 2.1 49.0 6.9 34.2 0.9 .2.3 2.0.5 1.4 1.1 1.0 .5 99 17 60 91 58 106 15 17 15 16 19 17 3.5 .7 3.1 3.6 2.5 3.0 .8 3.7 4The severity rate is the average number of days lost for each thousand employee-hours worked. • Number of establishments reporting. T a b l e 6. — Plant rules relating to the use of personal protective equipment in Goggles ________________________ Respirators___ _________________ Gloves . ___ GftS mfislrs Fa.ee shields ___________ Severity Resulting in— Average number Em of days lost Num ployeecharged Death Per Tem or ber of hours per injury All and per Death Per Tem dis manent- manent- porary em worked Severity ployees (thou Total or per manent- porary- abling total partial total rate 4 manent- partial total injuries dis dis dis sands) Tem total dis dis abilities abilities All dis poraryabilities dis abling total ability 8 ability ability injuries dis abilities 1 Totals include figures not shown separately because of insufficient data. *Figures in parentheses indicate the number of permanent-total disability cases included. * The frequency rate is the average number of industrial injuries for each million employee-hours worked. Type of equipment Frequency rates of8— 621 fertilizer manufacturing plants, 1946 Type of equipment Aprons __ 36.7 Safety shoes. _ 47.6 52.0 H oods____ .... __ 79.3 Rubber trousers.............................. 92.9 Finger guards.................................. 93.5 Coveralls Plants requiring Plants having no use in certain requirements operations Percent Number Percent of total Number of total 30 14 2 1 1 1 5.8 2.7 .4 .2 .2 .2 491 507 519 520 520 520 94.2 97.3 99.6 99.8 99.8 99.8 2 7 T able 7.— Disabling and medical injuries in 185 fertilizer establishments, classified by part of body injured and by extent of disability, 1946 Total number of disabling and medical injuries1 Part of body injured __ Total _ Shoulder_______________________ Other __ ___________________ Upper eytrorpi tie«? Anm(s) (inelnd in cr wrist) Hand(s) Finger(s) aud/nr th n m h (s).............. Lower extremities...................................... Ti.eg(s) Foot (including ankle) or feet__ Toe(s)_______________________ Body—Oeneral Unclassified; insnffifierit. data _ __ _ _ 2,532 585~ 424 48 113 538 98 231 67 37 58 47 658 103 186 369 684 228 371 85 45 22 100.0 23.2 16.9 1.9 4.5 21.4 3.9 9.1 2.7 1.5 2.3 1.9 26.2 4.1 7.4 14.7 27.3 9.1 14.8 3.4 1.8 100.0 14.1 9.1 1.6 3.4 26.6 4.1 12.3 3.9 1.9 2.3 2.1 22.6 4.7 6.6 11.3 34.4 11.0 19.2 4.2 2.3 1,238 172 110 20 42 326 50 151 48 23 28 26 277 58 81 138 421 135 234 52 28 14 *A disabling injury is one which results in death or permanent impairment, or causes an inability to work extending beyond the day of injury. A medical i njury is a nondisabling injury requiring treatment by a physician or surgeon. Number of medical Average injuries Average number number of medical of days injuries lost per Perma per dis tempo nent- Tempo rary-total abling partial rary-total disability Number Percent * injury disabil disability ity Resulting in— Death or perma Number Percent* Number Percent * nent-total disabil ity 3 Total_____________________________ Head........................................................... Eye(s)___ Brain nr slrnll___________________ .............. _ Other_________________________ Trunk____ ____ _____ nhfist. (Jungs), ribs, etc_____________ _______________________ Back Abdomen . ... . __ "PTip(s) nr pelvis Number of disabling injuries (2) 8 (1) 4 (1) 3 1 3 3 (1) 1 (1) 1 31 2 2 3 2 1 22 1 3 18 3 2 1 1 1,199 166 108 17 41 320 47 149 48 22 28 26 255 57 78 120 417 134 232 51 27 14 15 87 12 10 16 10 14 30 14 16 13 14 16 14 14 17 20 16 13 16 1,294 413 314 28 71 212 48 80 19 14 30 21 381 45 105 231 263 93 137 33 17 8 100.0 32.1 24.4 2.2 5.5 16.5 3.7 6.3 1.5 1.1 2.3 1.6 29.6 3.5 8.2 17.9 20.5 7.2 10.7 2.6 1.3 1.0 2.4 2.9 1.4 1.7 .7 1.0 .5 .4 .6 1.1 .8 1.4 .8 1.3 1.7 .6 .7 .6 .6 .6 * Percents are based on classified cases only. 3 Figures in parentheses indicate the number of permanent-total disability cases included. T able 8.— Disabling and medical injuries in 186 fertilizer establishments, classified by nature of injury and by extent of disability, 1946 Total number of disabling and medical injuries1 Nature of injury Total.......................................................... Amputations, „.. „......... - __Bruises, contusions.................................... Without infactinn ., With infection ... Burns, scalds (except chemical burns) Chemical burns __________________ Without infection ___________ With infection.- _______________ Cuts, lacerations, punctures..................... Without infection............................... With infection Foreign bodies in eyes, ears .. ... ... Fractures.................................................... Hernias________________ .. ... .... ... . Tudustriaisprains difiAflSAfi ______________ __________ strains, ____ Other.......................................................... Unclassified; insufficient data T. r Number of disabling injuries Total Death or perma Number Percent * Number Percent * nent-total disabil ity 3 2,532 18 828 807 21 84 248 238 10 489 454 35 191 122 22 37 434 27 32 100.0 .7 33.0 32.2 .8 3.4 9.9 9.5 .4 19.6 18.2 1.4 7.6 4.9 .9 1.5 17.4 1.1 1,238 18 457 445 12 44 96 93 3 182 160 22 27 100 22 16 241 15 20 i A disabling injury is one which results in death or permanent impairment, or causes an inability to work extending beyond the day of injury. A medical injury is a nondisabling injury requiring treatment by a physician or surgeon. Number of medical Average injuries number of days lost per Perma tempo nent- Tempo rary-total partial rary-total disability Number Percent* disabil disability ity Resulting in 100.0 1.5 37.6 36.6 1.0 3.6 7.9 7.7 .2 14.9 13.1 1.8 2.2 8.2 1.8 1.3 19.8 1.2 (2) (1) (1) (1) 1 1 31 17 1 1 2 2 3 3 1 7 2 1 8 1 3 3 Average number of medical injuries per dis abling injury 1,199 15 1,294 100.0 1.0 453 442 11 44 94 91 3 178 156 22 27 92 22 16 241 12 20 12 12 18 16 11 11 8 13 13 13 6 41 50 11 12 11 371 362 9 40 152 145 7 307 294 13 164 22 21 193 12 12 29.0 28.3 .7 3.1 11.9 11.4 .5 23.9 22.9 1.0 12.8 1.7 1.6 15.1 .9 .8 .8 .8 .9 lie 1.6 23 1.7 1.8 .6 6.1 .2 1.3 .8 .8 3 Percents are based on classified cases only, * Figures in parentheses indicate the number of permanent -total disability cases included. 28 T able 9.— Disabling and medical injuries in 165 fertilizer establishments, classified by nature of injury and by departments 1946 Nature of injury Department Total number of disabling and medical Sulphuric acid Superphosphate Dry mixing Maintenance injuries1 department department department department Other depart Unclassified; in ments sufficient data Num Per Num Per Num Per Num Per Num Per Num Per Num Per ber cent* ber cent* ber cent* ber cent* ber cent* ber cent* ber cent* Total.................................................... 2,395 100.0 16 Amputations....................................... .7 Bruises, contusions............................. 780 33.0 79 3.3 Bums, scalds (except chemical)......... Chemical bums................................... 242 10.2 Cuts, lacerations, punctures.............. 464 19.6 Foreign bodies in eyes, ears................ 177 7.5 Fractures............................................. 112 4.7 Hernias ................................................ 18 .8 35 1.5 Industrial diseases............................... Strains, sprains.................................... 420 17.8 21 .9 Other. ................................................. Unclassified, insufficient data 31 134 100.0 1 .7 21 15.7 8 6.0 45 33.7 11 8.2 9 6.7 9 6.7 1 .7 3 2.2 24 17.9 2 *1.5 251 100.0 1,104 100.0 4 1.6 4 .4 65 26.0 425 39.2 11 4.4 15 1.4 57 22.8 81 7.5 51 20.4 218 20.2 10 4.0 54 5.0 5 2.0 44 4.1 2 .8 5 .5 8 3.2 13 1.2 34 13.6 212 19.6 31 1.2 10 .9 23 i A disabling injury is one which results in death or permanent impairment, or causes an inability to work extending beyond the day of injury. A medical injury is a nondisabling injury requiring treatment by a physician or surgeon. 498 100.0 5 1.0 133 26.9 36 7.3 32 6.5 97 19.6 79 16.0 33 6.7 6 1.2 2 .4 69 14.0 2 .4 4 169 100.0 1 .6 47 28.0 3 1.8 14 8.3 34 20.2 13 7.7 8 4.8 1 .6 4 2.4 42 25.0 11 .6 239 1 89 6 13 53 12 13 3 5 39 3 2 100.0 .4 37.4 2.5 5.5 22.4 5.1 5.5 1.3 2.1 16.5 1.3 * Percents are based on classified cases only, T able 10.— Disabling and medical injuries in 185 fertilizer establishments, classified by part of body injured and by nature of injury, 1946 Part of body injured Total number of dis abling and Ampu Braises, con medical tations tusions injuries1 Total_________________________________ 2,532 585 HeadFyc(s) . ___ 424 Brain or skull_______________________ 48 113 Other . — ____________ Trunk _ ___ 538 Chest (lungs), ribs, etc__________ 98 Back ___________________________ 231 Abdomen, _ _____ ___ 67 Hip(s) or pelvis ______ 37 Shoulder____ _____ ______________ 58 Other , .......... . —,____________ ____ 47 658 Upper extremities Arm(s^ , - - ______________ _ ____ 103 TTand(s) (including wrist)_______ ___ 186 Finger(s) ftnd/cr thnmb(s)_ 369 684 T^>wer extremities , 228 TiCg(s) . , - ___ Font, (including ankle) or feet 371 85 Toe(s)_________ ____________________ 45 Body—General__ _ - ___ ___ 22 Unclassified; insufficient data 18 15 1 14 3 1 2 Nature of injury Bums, Cuts, Foreign lacera body scalds Chem ical tions, in Frac (except chemi bums punc eyes, tures cal) tures ears 828 54 15 16 23 179 50 39 18 22 19 31 250 34 60 156 322 117 156 49 21 2 1 i A disabling injury is one which results in death or permanent impairment, or causes an inability to work extending beyond the day of injury. 84 38 28 10 5 1 1 2 1 21 8 9 4 14 8 6 248 194 178 16 4 6 2 1 3 1 25 11 12 2 22 11 11 489 82 8 31 43 7 21 1 1 2 244 21 63 160 151 46 94 11 5 191 191 191 122 2 1 1 20 59 2 4 43 8 9 26 56 10 23 23 1 Un classi Her Indus Strains, fied; trial sprains Other suffiin nias diseases cient data 22 22 22 37 7 1 6 18 161 1 5 4 1 1 1 5 1 434 8 1 7 268 10 182 22 H 32 H 50 15 305 106 30 76 2 27 g 1 7 12 11 1 2 2 5 32 1 1 3 1 1 1 5 1 2 2 7 52 16 A medical injury is a nondisabling injury requiring treatment by a physician or surgeon. 29 T able 11.— Disabling and medical injuries in 166 fertilizer establishments, classified by part of body injured and by department, 1946 Part of body injured Department Total number of disabling and medical Sulphuric acid Superphosphate Dry-mixing Maintenance injuries1 department department department department Other depart Unclassified; in sufficient data ments Num Per Num Per Num Per Num Per Num Per Num Per Num Per ber cent2 ber cent ber cent ber cent2 ber cent2 ber cent2 ber cent2 Total.................................................... 2,395 100.0 Head.................................................... 554 23.3 Eye(s)........................................... 404 17.0 45 1.9 Brain or skull_______________ Other—.......................................... 105 4.4 Trunk.................................................. 503 21.2 88 3.7 Chest (lungs), ribs, etc................ Back.............................................. 220 9.3 59 2.5 Abdomen...................................... 36 1.5 Hip(s) or pelvis............................ 55 2.3 Shoulder........................................ 45 1.9 Other............................................. Upper extremities............................... 622 26.2 99 4.2 Arm(s).......................................... Hand(s) (including wrist)........... 174 7.3 Finger (s) and/or thumb (s).......... 349 14.7 Lower extremities............................... 650 27.4 Leg(s)............................................ 219 9.2 Foot (including ankle) or feet__ 353 14.9 78 3.3 Toe(s)........................................... Body—General.................................... 45 1.9 TTnoJassifiAdj in s u f f ic ie n t d a t a ____ 21 134 100.0 44 32.9 39 29.2 1 .7 4 3.0 33 24.6 10 7.5 13 9.7 3 2.2 3 2.2 2 1.5 2 1.5 31 23.1 11 8.2 6 4.5 14 10.4 23 17.2 7 5.2 14 10.5 2 1.5 3 2.2 1 A disabling injury is one which results in death or permanent impairment, or causes an inability to work extending beyond the day of injury. A medical injury is a nondisabling injury requiring treatment by a physician or surgeon. T able 251 100.0 1,104 100.0 70 27.9 199 13.3 50 19.9 137 12.6 4 1.6 22 2.0 16 6.4 40 3.7 51 20.3 226 20.8 11 4.4 31 2.8 17 6.7 111 10.2 5 2.0 27 2.5 7 2.8 17 1.6 7 2.8 23 2.1 4 1.6 17 1.6 66 26.3 283 26.0 10 4.0 40 3.7 28 11.1 76 7.0 28 11.2 167 15.3 56 22.3 362 33.2 19 7.6 119 10.9 29 11.5 206 18.9 8 3.2 37 3.4 8 3.2 19 1.7 15 498 100.0 160 32.3 131 26.5 8 1.6 21 4.2 85 17.2 13 2.6 32 6.6 11 2.2 3 .6 10 2.0 16 3.2 135 27.3 17 3.4 38 7.7 80 16.2 104 21.0 32 6.5 58 11.7 14 2.8 11 2.2 3 169 100.0 40 23.8 25 14.8 5 3.0 10 6.0 53 31.6 11 6.5 25 14.9 6 3.6 3 1.8 4 2.4 4 2.4 43 25.6 12 7.1 13 7.7 18 10.8 32 19.0 11 6.5 16 9.5 5 3.0 1 239 41 22 5 14 55 12 22 7 3 9 2 64 9 13 42 73 31 30 12 4 2 100.0 17.3 9.3 2.1 5.9 23.2 5.1 9.2 3.0 1.3 3.8 .8 27.0 3.8 5.5 17.7 30.8 13.0 12.7 5.1 1.7 *Percents are based on classified cases only, 12.— Agencies involved in injury-producing accidents in 165 fertilizer plants, classified by operating department, 1946 Agency Department Total number of accidents Sulphuric acid Superphosphate Dry-mixing Maintenance department department department department Other depart Unclassified; in ments sufficient data Num Per Num Per Num Per Num Per Num Per Num Per Num Per ber cent 1 ber cent1 ber cent 1 ber cent 1 ber cent 1 ber cent 1 ber cent 1 Total______________ ___________ 2,395 100.0 157 6.7 Machines______________________ Mixers 41 1.7 Other............................................. 116 5.0 43 1.8 Hoisting apparatus............................. Conveyors.................. ........... ............. 113 4.8 49 2.1 Belt type_____ ______ _______ 49 2.1 Bucket type____ ____________ .6 Other______________________ 15 66 2.8 Boilers and tanks................................ 481 20.4 Vehicles............................. .......... . Mntnr trucks 22 .9 Tractnrs, paylnarlers, etc __ 143 6.1 217 9.2 Hand trucks................................. Wheelbarrows 26 1.1 61 2.6 Railroad cars................................ Other___ . _ . 12 .5 28 1.2 Electrical apparatus........................... Hand tools........................................... 226 9.6 Bars (crowbars, |punch [bars, 36 1.5 etc.)............................................ 60 2.5 Hammers...................................... 23 1.0 Torches (welding and burning).. 107 4.6 Other............................................. 1Percents are based on classified cases only. 134 100.0 7 5.3 1 .8 6 4.5 3 2.3 1 .8 1 .8 19 5 14.4 3.8 2 1 1 1 1 16 4 4 1 7 1.4 .8 .8 .8 .8 12.1 3.0 3.0 .8 5.3 251 100.0 1,104 100.0 23 9.3 67 6.2 15 6.1 1.9 21 8 3.2 46 4.3 6 2.4 14 1.3 17 6.9 64 5.9 7 2.8 30 2.8 8 3.3 24 2.2 2 .8 .9 10 11 1.0 10 4.0 34 13.8 316 29.1 14 1.3 11 4.5 77 7.1 16 6.5 163 15.0 1.2 3 20 1.8 3 1.2 38 3.5 1 .4 4 .4 2 .8 6 .6 54 5.0 17 6.9 .8 2 12 1.1 7 2.8 13 1.2 1 .4 2.9 7 29 Z7 498 100.0 41 8.3 .4 2 39 7.9 18 3.7 13 2.6 .4 2 101 2.0 .2 14 2.8 303 6.1 .6 14 2.9 71 1.4 .2 5 1.0 16 3.2 102 20.7 10 2.0 27 5.5 18 3.7 47 9.5 169 100.0 11 6.6 2 1.2 9 5.4 1 .6 5 3.0 22 1.2 1 1.2 .6 4 2.4 284 16.9 2.4 6 3.6 9 5.5 7 4.2 2 1.2 1 .6 12 7.2 1 .6 2 1.2 2 1.2 7 4.2 239 8 8 1 13 57 1 8 681 35 201 47 2 25 7 71 10 100.0 3.4 3.4 .4 5.5 3.0 2.1 .4 3.4 28.5 .4 14 7 8.4 .4 2.9 1.7 .8 10.5 2.9 2.9 .4 4.3 30 T able 12.— Agencies involved in injury-producing accidents in 165 fertilizer plants, classified by operating department, 1946— Continued Agency Chemicals............................................ Acids............................................ Fertilizer...................................... Other............................................. Working surfaces................................ Floors............................................ Platforms, scaffolds.................. Ramps (gangplanks).................... Other............................................. Containers.......................... ............... Bags.............................................. Other............................................. Miscellaneous Bins, pits...................................... Cables, ropes, wires, chains......... Foreign bodies (eye injuries)....... Ladders......................................... Lumber stock............................... Metal parts................................... Piles of material.......................... Stairs............................................. Other............................................. Unclassified; insufficient data............ Department Total number of accidents Sulphuric acid Superphosphate Dry-mixing Maintenance department department department department Other depart Unclassified; in ments sufficient data Num Per Num Per- Num Per Num Per Num Per Num Per Num Per ber cent 1 ber cent1 ber cent1 ber cent 1 ber cent 1 ber cent 1 ber cent1 165 7.0 18 13.6 39 15.8 79 7.3 11 6.6 11 4.6 37 1.4 41 1.7 15 6.1 11 8.3 10 .9 .6 2 1.2 1 g 24 1.0 2 2 .8 19 1.8 .2 100 4.3 7 5.3 22 8.9 50 4.6 3 .6 9 5.4 9 3! 8 307 13.0 15 11.4 24 9.7 154 14.2 54 11.0 21 12.7 16.4 39 159 6.8 8 6.1 14 5.7 86 7.9 25 5.2 7 4.2 8.0 19 46 1.9 4 3.0 4 1.6 14 1.3 16 3.2 3 1.8 5 2.1 54 2.3 1 1 .8 .4 39 3.6 1 .2 3 1.8 9 3.8 48 2.0 2 5 2.0 1.5 15 1.4 2.4 12 8 4.9 6 2.5 151 6.4 3 2.3 8 3.2 100 9.2 5 1.0 26 15.7 9 3.8 123 5.2 1 5 2.0 .8 95 8.7 2 .4 13 7.8 3.0 7 28 1.2 3 2 1.5 1.2 .5 5 .6 3 13 7.9 2 .8 623 26.3 44 33.2 67 27.2 219 20.2 193 39.2 46 27.7 54 22.7 39 1.7 2 1.5 13 5.3 14 1.3 1 6 1.2 3 .6 1.3 g 1 Q 27 1.1 8 2 .8 10 .9 16 25 101 4.3 8 6.1 7 2.8 279 2.5s 44 9.0 82 4! 8 2! 9 7 3 2.3 27 1.1 2 0 10 1.2 13 03 3.9 8 3.2 2 1.5 26 2.4 34 6*. 9 10 e!o 5.5 13 95 4.0 11 8.2 8 3.2 24 2.2 7.5 37 8 4.8 2.9 7 4 11 4.5 47 2.0 2 1.5 2 1.2 28 2.6 1.7 23 1.0 1 4 .8 1.6 11 1.0 2 .4 3 L8 2 '.S 7.2 171 14 5.8 15 11.3 11 6.7 9 70 6.5 52 10.6 3.8 35 5 3 1 4 2 20 T able 13.— Types of accidents resulting in injuries in 165 fertilizer plantsy classified by operating department, 1946 Department Total number of accidents Sulphuric acid Superphosphate Dry-mixing Maintenance Other depart Unclassified; in* Accident type department department department department ments sufficient data Num Per Num Per Num Per Num Per Num Per Num Per Num Per ber cent 1 ber cent1 ber cent 1 ber cent 1 ber cent 1 ber cent 1 ber cent 1 Total__________________________ 2,395 100.0 134 100.0 251 100.0 1,104 100.0 498 100.0 169 100.0 239 100.0 Striking against................................... 289~ 12.2 39~ 15.8 <uT 14r 12.9 52~ 10.5 IT 10.8 3r is n Struck by........... ............................ . 886 37.2 59 23.9 416 38.0 28 21.1 234 47.1 58 34.6 91 38.3 Caught in, on, or between.................. 279 11.7 10 7.5 27 10.9 14.3 157 36 7.2 14 8.4 35 14.8 Falls—Total......................................... 232 9.8 12 9.0 19 7.7 105 9.6 51 10.3 20 12.0 25 10.5 On same level............................... 109 4.6 4 3.0 9 3.6 68 6.2 8 1.6 10 6.0 10 4.2 To different level.......................... 123 5.2 10 4.1 8 6.0 3.4 37 43 10 8.7 6.0 15 6.3 Slips (not falls).................................... 57 2.4 6 2.4 5 3.8 24 2.2 12 2.4 5 3.0 5 2.1 Contact with extreme temperatures. 36 1.5 4 1.6 2 1.5 9 .8 16 3.2 1 .6 4 1.7 Inhalation, absorption, ingestion....... 308 13.0 74 30.0 53 39.8 106 9.7 32 6.4 22 13.2 21 8.9 Overexertion........................................ 252 10.6 15 11.3 6.9 17 129 11.8 42 8.5 28 16.8 21 8.9 Other................................................... 37 1.6 2 .8 8 .7 22 4.4 1 .6 4 1.7 Unclassified; insufficient data............ 19 4 1 9 2 1 2 1Percents are based on classified cases only. — 31 T able 14.— Agencies and unsafe working conditions involved in injury-producing accidents in 158 fertilizer plants, 1948 i 1 m Total........................................... 2,387 194 444 27 114 61 17 1 1 Machines_________________ 160 Mixers_________________ 42 11 116 1 1 Other. ____ _____ 118 60 Hoisting apparatus _ 1 14 49 52 19 Conveyors_________________ 111 Belt type 47 28 6 Bucket type___ ________ 48 195 94 O ther....I........................... 16 Boilers and tanks. . _______ 63 3 22 9 62 4 7 466 Vehicles........................-............. M otor trunks 2 19 3 1 Tractors, payloaders, etc__ 164 4 29 11 1 200 Hand trucks____________ Wheelbarrows _ 1 22 Railroad ears 68 3 17 2 5 Other.. _ 13 2 1 Electrical apparatus.. _ _ 27 7 8 Hand tools................................ 218 7 26 1 Bars (crowbars, punch bars, etc.)_________________ 33 10 Hammers_____ _________ 67 Torches (welding and burning)_____________ 26 1 1 Other__________________ 103 6 15 i Chemicals___ . . . . . ... 162 39 A cid ______________________ 22 Fertilizer_______________ Other . 101 Working surfaces........................ 314 28 179 12 94 Floors.................................. 168 6 96 81 605 Platforms, scaffolds............. 44 11 26 Ramps (gangplanks)_____ 61 4 36 1 17 Other. _ ________ 51 7 21 2 12 Containers 14 3 154 Bags . ^ r . ___ 127 6 Other . . . . 27 8 3 Miscellaneous............................ 632 24 83 6 121 Bins, pits______________ 39 2 14 Cables, ropes, wires, chains. 25 7 Foreign bodies (eye in juries! 106 Ladders . 28 9 2 Lumber stock 13 2 91 6 Metal parts_____________ 97 Piles of material_________ 51 9 Stairs.................................... 23 10 Other.................................... 172 13 31 4 2 2 Unclassified; insufficient data—. 31 1 I gS 5* 1 * * % 43 GQ bfi Lack of personal Hazardous arrangements or procedures safety equipment s S&8 ©Q I If 1 n i ii it I S 1 " I*s £<+> °m B.1 o § j3 © ® s J *1 IO 3Ho I6 1e* O© 1O 1 1 1 0§45 a 0 67 115 121 437 4 11 11 31 2 5 9 6 1 10 3 10 5 4 10 5 1 1 4 5 2 4 1 3 3 1 10 11 12 11 8 32 63 1 3 1 3 24 22 3 2 5 26 1 2 6 3 1 8 1 2 1 7 4 20 5 23 5 9 1 6 1 2 11 3 10 9 4 2 3 24 29 20 67 49 17 11 2 11 7 2 2 3 13 4 3 4 12 2 8 1 88 1 4 1 83 1 4 5 23 21 21 144 2 5 6 6 2 5 2 8 3 2 1 2 5 9 2 1 1 11 2 27 31 39 1 36 1 91 1 1 2 2 5 2 3 4 1 1 2 1 1 11 10 1 66 1 16 10 34 5 1 63 115 139 7 3 5 2 3 5 3 2 1 1 6 3 2 43 7 1 16 4 19 1 2 2 5 2 4 19 4 5 2 8 9 4 2 3 60 1 1 47 2 1 1 11 75 73 2 1 25 411 2 1 1 1 1 1 5 14 29 126 109 15 14 6 6 9 8 2 1 4 3 1 22 21 3 6 2 3 1 17 1 1 1 1 12 1,174 56 14 42 24 31 11 16 4 18 3 325 13 3 94 162 19 29 8 8 8 4 2 1 i 2 2 13 1 2 5 5 62 9 15 38 13 1 2 5 5 51 8 14 29 111 1 9 2 2 1 1 1 1 18 4 17 4 1 31 7 7 7 6 1 2 2 1 1 | Unclassified; insufficient data Defective agencies Other unsafe conditions Improperly guarded agencies Agency Total number of accidents Unsafe working conditions 8 4 2 1 1 2 2 11 31 9 20 1 11 6 1 1 5 5 148 27 39 15 67 86 26 5 55 40 17 5 7 11 50 36 14 360 12 16 99 15 51 60 12 12 83 28 32 T able 15.— Unsafe working conditions involved in injury-producing accidents in 148 fertilizer plants, classified by operating department, 1946 Unsafe working condition Department Total number of accidents Sulphuric acid Superphosphate Dry-mixing Maintenance department department department department Other depart Unclassified: in ments sufficient data Num Per Num Per Num Per Num Per Num Per Num Per Num Per ber cent 1 ber cent1 ber cent1 ber cent 1 ber cent1 ber cent 1 ber cent1 Total.................................................... 2,264 100.0 132 100.0 244 100.0 1,021 100.0 474 100.0 153 100.0 230 100.0 Improperly guarded agencies............. 188 16.3 12.5 10 18 15.0 82 15.1 49 21.9 12 15.4 17 15.2 Defective agencies............................... 417 36.0 43 35.8 28 34.9 193 35.6 77 34.3 28 35.9 48 42.8 Rough............. ............................. 2.2 26 1 3 1.3 2.5 15 2.8 2 .9 1 1.3 4 3.6 Slippery........................................ 106 9.2 6 5.0 6 7.4 67 12.3 8 3.6 7 9.0 12 10.7 Sharp-edged _ _ __ 63 6.4 3.8 3 9 7.5 31 5.7 7 3.1 5 6.4 8 7.1 Aged, worn, cracked, etc............. 110 9.6 11 13.6 10 8.3 32 5.9 40 17.8 8 10.2 9 8.0 Other............................................. 112 9.7 15 8.8 7 12.5 48 20 8.9 8.9 7 9.0 15 13.4 Hazardous arrangements or pro cedures.............................................. 416 36.0 41 34.2 199 36.8 27 33.8 73 32.6 33 42.3 43 sa 4 Unsafely stored or piled mate rials, etc..................................... 11 9.2 87 7.5 5.0 4 46 8.5 10 4.5 7 9.0 9 ao Lack of clear walkways or work ing surfaces................................ 61 5.3 1 1.3 8 25 6.7 4.6 15 6.7 4.5 7 9.0 5 Unsafe planning or lay-out of traffic or process operations___ 106 9.2 12 14.9 14 11.6 42 18 8.0 7.7 4 5.1 16 14.3 Lack of proper lifting equipment- 134 11.6 5 4.2 7 8.8 75 14.0 26 11.6 11 14.1 10 ao other............................................. 28 2.4 3 3 3.8 2.5 11 2.0 4 1.8 4 5.1 3 2.7 Lack of personal safety equipment— 126 10.9 15 18.8 14.2 17 63 11.6 23 10.3 4 5.1 4 3.6 Goggles-........................................ 109 9.4 12 15.0 12 10.0 21 57 10.5 9.4 4 5.1 3 2.7 Other............................................ 17 1.5 3 3.8 5 4.2 6 1.1 .9 1 .9 Other unsafe conditions...................... 9 .8 1 2 .8 5 .9 .9 1 1.3 Unclassified; insufficient data______ 1,098 52 124 479 250 75 118 1 Percents are based on classified cases only. T able 16.— Unsafe acts involved in injury-producing accidents in 160 fertilizer plants, classified by operating department Unsafe act Total number of accidents Department Sulphuric Superphos Dry-mixing Maintenance Other depart Unclassified; acid depart phate depart department insufficient department ments ment ment data Num Per Num Per Num Per Num Per Num Per Num Per Num Per ber cent 1 ber cent 1 ber cent 1 ber cent i ber cent 1 ber cent 1 ber cent 1 Total........................................................................... 2,387 134 ===== 100.0 ----100.0 = 251 -- ' ~===== ■ — = =100.0 = =1,099 = - 100.0—= =497: 100.0- —■ —169■— 100.0— . 237.— 100.0 Operating without authority, failure to secure or warn______ ______________________________ 67 4.1 6 7.6 6 3.4 18 2.4 22 6.6 8 7.3 7 4.1 Operating or working at an unsafe speed................. 199 12.3 4 5.1 10 5.6 137 18.3 9 2.7 9 8.2 30 17.6 Driving or operating too rapidly, slowly, or carelessly........................................................... 66 4.1 1 1.3 4 2.2 35 4.7 3 .9 4 3.7 19 11.1 Using hand trucks unsafely or carelessly........... 99 6.1 1 1.3 5 2.8 80 10.7 1 .3 4 3.6 8 4.7 Other..................................................................... 34 2.1 2 2.5 1 .6 22 2.9 5 1.5 1 .9 3 1.8 26 32.9 Using unsafe equipment or equipment unsafely— 543 33.7 47 26.4 246 32.8 135 40.9 28 25.5 61 35.9 10 12.6 19 10.6 38 5.1 Unsafe use of equipment____ _____________ 150 9.4 65 19.8 8 7.2 10 5.9 Gripping objects insecurely................................ 130 8.0 6 7.6 9 5.1 57 7.6 36 10.9 6 5.5 16 9.4 5 6.3 Taking wrong hold of objects............................. 115 7.1 9 5.1 52 6.9 21 6.3 6.4 7 21 3 12.3 Pulling instead of pushing hand trucks.......... 55 3.4 1 1.3 1 2 1.1 48 6.4 3 1.8 Other.................................................................... 93 5.8 4 5.1 8 4.5 51 6.8 12 3.6 7 6.4 11 <U 5 6.3 6 3.4 Unsafe loading, placing, mixing, etc......................... 59 3.6 21 2.8 15 4.5 5 4.5 7 4.1 17 21.5 33 18.5 Failure to use personal safety equipment................. 176 10.9 6.7 50 53 16.0 13 11.8 10 5.9 13 16.4 27 15.1 Goggles................................................................. 142 8.8 37 5.0 50 15.1 11 10.0 4 2.4 Other____________ _____________________ 34 2.1 4 5.1 6 3.4 13 1.7 3 .9 2 1.8 6 3.5 18 22.8 Taking unsafe positions or postures.......................... 538 33.3 70 39.3 260 34.7 90 27.2 45 40.9 55 32.4 Exposure to falling or sliding objects................. 48 3.0 1 1.3 11 6.2 25 3.3 1.8 1 .9 4 2.4 9 11.3 36 20.2 159 21.3 476 14.3 Inattention to footing......................................... 306 19.0 26 23.7 29 17.1 4 5.1 Lifting incorrectly............................................... 80 4.9 8 4.5 30 4.0 17 5.1 13 11.8 8 4.7 4 5.1 Other.................................................................... 104 6.4 15 8.4 46 6.1 20 6.0 5 4.5 14 8.2 3 3.8 Working on moving or dangerous equipment......... 28 1.7 6 3.4 14 1.9 11 .9 4 1.2 7 .4 Other......................................................................... 3 .4 3 .9 .9 55 73 Unclassified; insufficient data_________________ 770 350 166 59 67 1 Percents are based on classified cases only. U. S. GOVERNMENT PRINTING OFFICE: 194# Recent Bureau of Labor Statistics Reports on Industrial Hazards and Working Conditions* Injuries and accident causes in the longshore industryf 1942. Bulletin No. 764. (Out of print. Copies are on file in many libraries.) A detailed analysis of the hazards involved in loading and unloading ships. Includes sample safety codes and accident prevention suggestions. Injuries and accident causes in the foundry industry, 1942. Bulletin No. 806. Price 15 cents. An analysis of foundry accidents and their causes, including accident prevention suggestions. Present comparisons based upon plant size, geographic location, first-aid facilities, type of product, and departmental operations. Injuries and accident causes in the slaughtering and meat-packing industry, 1943. Bulletin No. 855. Price 15 cents. A detailed analysis of Ihe hazards and of the prevailing causes of accidents in the meat industry, in cluding comparisons based upon depart menial, regional, and plant-size factors. Also includes descriptions of typical accidents, accompanied by suggestions for the prevention of similar occurrences. Injuries and accident causes in the brewing industry. 1944• Bulletin No. 884. Price 15 cents. Presents a detailed account of the accident record of brewery workers during 1944, with frequency rate comparisons based upon tIso operating divisions of the plants, the size of the plants, and the geographic location of the plants. Also includes an analysis of the causes of brewery accidents and suggestions for the prevention of typical brewery accidents. Injuries and accident causes in the pulpwood logging industry, 1943 and 1944• Bulletin No. 924. Price 10 cents. A detailed account of the hazards and of the prevailing causes of accidents in the various operations of the pulpwood logging industry. Work injuries in the United States during 1947. Bulletin No. 945. Price 15 cents. A collection of basic industrial injury data for each of the major industries in the United States. Pre sents national average injury-frequency and severity rates for each industry. Individual establishments may evaluate their own injury records by comparison with these data. The performance of physically impaired workers in manufacturing industries. Bulletin No. 923. Price 55 cents. Presents comparisons between impaired and unimpaired workers in respect to productivity, efficiency, absenteeism, accidents, and turn-over. Hours of work and output. Bulletin No. 917. Price 35 cents. A study of the changes in efficiency, total output, absenteeism, and accidents resulting from changes in the length of the workday or workweek. Workmen’s compensation and the protection of seamen. Bulletin No. 869. Price 20 cents. A report on the financial protection afforded merchant seamen who are disabled because of injury or disease while in the service of their vessels. Presents the status of such seamen under both foreign and domestic legislation and examines the probable results of applying to seamen the recommendations of an interdepartmental committee for a workmen's compensation act fitted to the existing rights of merchant seamen. *For sale by Superintendent of Documents at prices indicated. How to order publications: Address your order to tho Superintendent of Documents, Government Printing Cilice, Washington 25, D. C., with remittance in cheek or money order. Currency is sent at sender’s risk. Postage stumps not acceptable.
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