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Inspection Detail
Inspection: 102595469 - Ak Steel Corporation
Inspection Information - Office: Cincinnati Area Office
Site Address:
Ak Steel Corporation
1801 Crawford St.
Middletown, OH 45043
Mailing Address:
, , 00000
Union Status: Union
SIC:3312
NAICS: 0
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 03/29/1996
Planning Guide: Safety-Manufacturing
Emphasis:
Case Closed: 09/17/1996
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 360169908 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 5 | 14 | 19 | |||
| Current Violations | 19 | 19 | ||||
| Initial Penalty | $35,000 | $980,000 | $0 | $0 | $0 | $1,015,000 |
| Current Penalty | $0 | $0 | $0 | $0 | $710,000 | $710,000 |
| FTA Penalty | $0 | $0 | $0 | $0 | $0 | $0 |
| # | Citation ID | Citaton Type | Standard Cited | Issuance Date | Abatement Due Date | Current Penalty | Initial Penalty | FTA Penalty | Contest | Latest Event | Note |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1. | 01001 | Unclass | 19100147 C04 I | 04/01/1996 | 04/11/1996 | $5,000 | $7,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 2. | 01002 | Unclass | 19100147 C05 II | 04/01/1996 | 04/04/1996 | $5,000 | $7,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 3. | 01003 | Unclass | 19100147 C07 I | 04/01/1996 | 04/25/1996 | $5,000 | $7,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 4. | 01004 | Unclass | 19100147 D01 | 04/01/1996 | 04/11/1996 | $5,000 | $7,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 5. | 01005 | Unclass | 19100147 D06 | 04/01/1996 | 04/04/1996 | $5,000 | $7,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 6. | 02001 | Unclass | 19100147 C04 I | 04/01/1996 | 04/25/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 7. | 02002 | Unclass | 19100147 C06 I | 04/01/1996 | 04/25/1996 | $48,928 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 8. | 02003 | Unclass | 19100147 C08 | 04/01/1996 | 04/04/1996 | $48,928 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 9. | 02004 | Unclass | 19100147 D03 | 04/01/1996 | 04/04/1996 | $48,928 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 10. | 02005 | Unclass | 19100147 D03 | 04/01/1996 | 04/04/1996 | $48,928 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 11. | 02006 | Unclass | 19100147 D03 | 04/01/1996 | 04/04/1996 | $48,928 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 12. | 02007 | Unclass | 19100147 D03 | 04/01/1996 | 04/04/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 13. | 02008 | Unclass | 19100147 D03 | 04/01/1996 | 04/25/1996 | $48,928 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 14. | 02009 | Unclass | 19100147 D04 I | 04/01/1996 | 04/04/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 15. | 02010 | Unclass | 19100147 D04 I | 04/01/1996 | 04/04/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 16. | 02011 | Unclass | 19100147 D04 I | 04/01/1996 | 04/04/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 17. | 02012 | Unclass | 19100147 D04 I | 04/01/1996 | 04/04/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 18. | 02013 | Unclass | 19100147 D04 I | 04/01/1996 | 04/04/1996 | $48,929 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement | |
| 19. | 02014 | Unclass | 19100147 D04 I | 04/01/1996 | 04/04/1996 | $48,934 | $70,000 | $0 | 05/03/1996 | F - Formal Settlement |
Investigation Summary
Employees #2 and #3, maintenance workers, were attempting to straighten a bent pipe on the hydraulic system of the south tundish car in the caster department. They were using a hand winch to pull on the pipe and a torch to heat it when the pipe ruptured and a flash fire occurred. Employees #2 and #3 were hospitalized with burns. Employee #1, a production worker in the area, was also burned and subsequently died. The hydraulic system pump had been deenergized but not locked out, and the system had not been bled of residual pressure. It appeared that someone had restarted the pump prior to the accident.
Keywords: BURN, MAINTENANCE, WORK RULES, FIRE, LOCKOUT, RUPTURE, PIPE
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 102595469 | Fatality | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 2 | 102595469 | Hospitalized injury | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 3 | 102595469 | Hospitalized injury | Burn/Scald(Heat) | Machinery maintenance occupations |