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Occupational Safety and Health Administration OSHA

Inspection Detail

Case Status: OPEN

Note: The following inspection has not been indicated as closed. Please be aware that the information shown may change, e.g. violations may be added or deleted. For open cases, in which a citation has been issued, the citation information may not be available for 5 days following receipt by the employer for Federal inspections or for 30 days following receipt by the employer for State inspections.

Inspection: 1488744.015 - Polyplex Usa Llc

Inspection Information - Office: Birmingham


Inspection Nr: 1488744.015
Report ID: 0418300
Open Date: 08/18/2020

Site Address:
Polyplex Usa Llc
3001 Mallard Fox Drive Nw
Decatur, AL 35601

Mailing Address:
3001 Mallard Fox Drive Nw, Decatur, AL 35601

Union Status: NonUnion


NAICS: 326199/All Other Plastics Product Manufacturing

Inspection Type: Referral

Scope: Partial

Advanced Notice: N

Ownership: Private

Safety/Health: Safety

Close Conference: 02/05/2021


Close Case:

Related Activity
Type Activity Nr Safety Health
Referral 1643083 Yes
Case Status: OPEN
Violation Summary
Violations/Penalties Serious Willful Repeat Other Unclass Total
Initial Violations 1 1 2
Current Violations 1 1 2
Initial Penalty $27,032 $135,167 $0 $0 $0 $162,199
Current Penalty $13,516 $0 $76,484 $0 $0 $90,000
FTA Penalty $0 $0 $0 $0 $0 $0

Violation Items
# Citation ID Citaton Type Standard Issuance Date Abatement Due Date Current Penalty Initial Penalty FTA Penalty Contest Latest Event Note
1. 01001A Serious 19100147 C04 I 02/08/2021 11/22/2022 $13,516 $13,516 $0 03/08/2021 J - ALJ Decision  
2. 01001B Serious 19100147 C04 II D 02/08/2021 11/22/2022 $0 $0 $0 03/08/2021 J - ALJ Decision  
3. 01001C Serious 19100147 D 02/08/2021 11/22/2022 $0 $13,516 $0 03/08/2021 J - ALJ Decision  
4. 02001 Repeat 19100132 A 02/08/2021 11/22/2022 $76,484 $135,167 $0 03/08/2021 J - ALJ Decision  

Investigation Summary

Investigation Nr: 128789.015
Event: 08/12/2020
Employee Is Severely Burned During Line Break

At 11:45 a.m. on August 12, 2020, an employee was pulling on a dosing nozzle to remove it from an isolated line between two reactors. A coworker had closed the two hand valves to isolate the line, drilled a hole up into the drain valve disc harge opening to unplug the monomer that had solidified in the line due to valve leakage, and attempted to open the drain valve but could not get it to open. Th e employee said he saw a resin drain from the line then waited about 45 minutes to an hour before breaking the line. Another coworker had removed the flange ov er the nozzle and attempted to pull the nozzle out of the line but had to take a break due to overheating. The employee was only wearing heat gloves and an alu minized hood with a face shield when they took over to try to pull on the nozzle . When the nozzle came unstuck, the employee was sprayed with the monomer consi sting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 500 degrees F, or 260 degrees C. The employee was admitted and treated at the hospital for third degree burns runnin g along the right forearm and second degrees burns to the stomach and knee.

Keywords:abdomen, arm, burn, chemical burn, chemical exposure, chemical reaction, chemical vapor, flowing material, forearm, heat-related illness , knee, leak, overheated, reactor, sprayed, stomach, stuck, valve

Investigated Inspection
# Inspection Age Sex Degree Nature Occupation
1 1488744.015 Hospitalized injury Technicians, n.e.c.
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