OSHA Houston Area Overview and Statistics 2011

OSHA FY2011 Houston Area Overview
and Selected Federal Statistics
Jim Shelton, CAS, HNAO

Houston OSHA Inspections
• In FY 2011 the Houston OSHA offices did
approximately 995 inspections:
2,134 citations were issued (2,889 FY10)
1,735 citations were Serious (1,971 FY10)
70 citations were Repeat (59 FY10)
8 citations were Willful
– No citations in about 30% of inspections
– Penalties proposed were $6,570,203
– 10 Significant Cases

Fatalities/Catastrophes Disclaimer
• The R-VI FAT/CAT numbers are based on inspections
conducted with limited editing. The numbers were pulled
Oct 6, 2001 and records could potentially be deleted or
added based on various activities… Houston fatalities
were edited and data adjusted, for example one Houston
record removed due to its being a heart attack and
several were not within OSHAs jurisdiction.. While one
was a double fatality. Region VI numbers due to the
volume are used ‘as is’. The IMIS information used here
is for informational and safety awareness purposes only,
not a statistical study and should not be used or
referenced in that way.

Fat/Cat Investigations - IMIS Records

Houston Fatality Investigations

Fatality Investigations – Tot vs.Cnst

Fatality Investigations - % Cnst/O&G

Houston Construction Fatalities
• SIC 1721 – 35 year old employee operating an
aerial lift painting. While attempting to position the
aerial lift employee had his back to the building and
either moved the aerial lift or boomed out pinning
him between the building and control station inside
the lift
• SIC 1741 – A 27 year old employee at an apartment
complex being built was sponge coating the stucco
from a tubular welded scaffold 13’ high when he fell
striking cross bracing on an adjacent scaffold and
then the ground

• SIC 1799 – 47 year old employee and four others
were working on blinding flanges on a valved pipeline
manifold system when a fire broke out. The other four
employees were able to escape and evacuate
• SIC 1791 – A 22 year old connector was preparing to
connect a structural beam to be positioned with a
crane. Another connector was at the other end. The
crane positioned the beam and they began to connect
the beam. A column collapsed causing the employee
to fall 50 as the beam his fall protection was
connected to collapsed and was pinned by the beam

• SIC 1799 – 57 year old employee part of a crew
installing new pipe to a storage tank that had been
previously used, and drained two days prior, for
storing a coal tar naphtha product. Employee was
working on the ground helping to align a pipe to be
arc welded. Employees working on an aerial lift
struck an arc and the tank exploded. Employee died
after being struck by a falling section of elevated
walkway
• SIC 1741 – A 33 year old bricklayer on his first day
of work died of heat stroke

• SIC 1771 – A 47 year old concrete finisher working
on a project. A concrete driver arrived and
dismounted from the truck and went to the rear of
the vehicle preparing to discharge the concrete. As
the switch was activated the engine RPMs rose
sharply and the vehicle surged forward pinning an
employee against a concrete retaining wall impaling
his leg in rebar, another was pushed into a retaining
wall and the deceased was run over
• SIC 1771 – A crane was removing a concrete
gangform when the gangform swung parallel to a
wall crushing a 25 year old employee between the
gangform and the concrete wall

• SIC 1771 – A cement driver was stuck on a hole of
loose soil. Another driver used a grader and chain to
pull the truck out which failed. The driver backed
another cement truck up to the front bumper of the
stuck truck and connected a 20’x6” sling onto the
hook at the rear of the truck. The driver of the pulling
truck drove off without taking the slack out of the sling
causing the hook to break away and traveled 100’
striking a 32 year old worker in the arm and chest
• SIC 1799 – A 46 year old employee filling buckets
with water from boiler blow down sump when he lost
his balance and fell into the condensate pit and
received severe thermal burns on 85-90% of his body

• SIC 1795 – A 66 year old employee on a demolition
project where a section was being removed. He went
to retrieve containers of diesel from under the level
being removed three sections down when the level
being removed collapsed on the employee
• SIC 1761 – A 21 year old employee working on a 30’
high roof taking measurements and painting marks
prior to installing a warning line. One employee was
holding the measuring tape while the employee
walked backwards with the measuring tape and
walked backwards off the roof

• SIC 1611 – A road with N and S bound lanes had
cones set up to stop traffic and then proceed
southbound or opposing lane with caution. Flaggers in
place with radio contact on the N and S bound lanes to
stop traffic. The 23 year old flagger stopped the N
bound lane traffic from the shoulder of the road. A
vehicle stopped but the vehicle behind did not slow
down and when they saw they would hit the car turned
onto the paved shoulder striking him
• SIC 1721 – A 39 year old painter spray painting exterior
of an apartment complex with OH power line 3.5’ away
when he or his equipment touched the line
electrocuting him

• SIC 1731 – A 32 year old electrician working on a
scissor lift about 15’ switching the 277 volt circuits of
the lights from emergency lighting to a regular wall
switch. The collapsable guardrails at the midrail
were in the down position leaving the rails at a
height of 22”. The employee was working on the
energized lights and was electrocuted and fell off the
scissor lift to the ground
• SIC 1761 – A 59 year old employee doing stucco
work from 2nd
tier of scaffold 14’ high when he fell
through the 16-18” opening between the house and
scaffold as he tried to take a measurement.

• SIC 1541 – A 80 year old employee was on a crew
erecting a metal building. The employee was on the
top of the building placing metal roof sheathing
when he fell from the roof 16’ to the concrete below
• SIC 1794 – A 48 year old employee was installing a
2 inch water line and tracer wire in a trench 6.5’
deep and 2’ wide when the trench wall and spoil pile
above him caved in and covered him. He was
trapped 6-8 minutes when pulled out and died 6
days later
• SIC 1771 – A 39 year old employee working on
drainage inlet where a front end loader was running.
The loader was in park with brake set when it rolled
forward striking employee

Houston General Industry
• SIC 1381 – A 27 year old employee was electrocuted
when his body made contact with a 480 volt
energized I-beam on an oil well platform
• SIC 8711 – Two employees walked from a
maintenance spur to an active guide way of an
elevated passenger transport rail system towards a
switch pit area 42’ away. An unmanned train was
stopped to pick up passengers. Employees were
inspecting a set of handrails near the switch pit when
the train departed and struck the employees killing
the 57 year old as they walked back to the
maintenance spur

• SIC 5169 – A 43 year old technician connected the
pumping system to a tanker truck and began pumping
out lighter fluid. Later an employee walking through
the area saw him walking clutching his throat and
gasping for air and then collapsed. The technician
had suffered a blunt force injury on the neck
• SIC 4491 – A 49 year old employee conducting
checking activities at a marine terminal. As she was
checking a cargo truck the driver pulled forward
causing employee to fall under the wheels of the
trailer and was run over.

• SIC 3498 – A 31 year old pipe threading machine
operator hit his leg against the edge of a scrap metal
dumpster. He told a supervisor who saw the cloth
wrapped on the leg he wasn’t hurt it was just sore
and didn’t want it looked at. Two days later he was
transported to a hospital for infection and gangrene
that spread to both legs. A leg was amputated and
two days later he died from complications
• SIC 5411 – A 50 year old employee removing a
component from a dock leveler being tilted vertically
by a forklift. The leveler slipped off the forks and
crushed him

• SIC 5063 – A 61 year old employee was replacing a
hose becoming disconnected from a compressor
system. Hose was replaced and later went back to test
hose and fitting for leaks with a leak detector. The
sound of escaping air was heard and he was found with
head injury laying by disconnected replacement hose
• SIC 1389 – A 40 year old employee helping to
assemble a rig derrick. Preparing to hook a section of
derrick to the crane he was observed climbing a section
of derrick which fell backwards against another section
of derrick pinning him

• SIC 5261 – A 50 year old nursery worker going
to join the rest of the work crew at another work
location died when he rode his bicycle off a
loading dock 4’ high
• SIC 3498 – A 48 year old truck driver was
loading sprinkler pipes onto a flatbed trailer
using a forklift. He exited the forklift to reposition
the load while elevated above the trailer when
the forklift moved forward pinning him against
the trailer

• SIC 5099 – A 23 year old employee unloaded a
trailer at the receiving dock. After unloading the
supplies the truck moved away from the dock and
he jumped from the dock to repair rubber pads that
had broken off the day before. The truck rolled
backwards pinning him between bumper and dock
• SIC 4491 – A 38 year old employee climbed into the
hold of the ship to put a strap around bundles of
steel. The bundles broke loose and rolled onto him
pinning him under the steel

• SIC 3069 – A 24 year old rigger was on a crew in the
process of moving a 16’ spool with a forklift. He was
walking along the side of the forklift as a spotter when
the forklift ran over him with a back tire
• SIC 1389 – A 22 year old employee was in close
proximity to a ball valve while operating a manual
choke manifold on a natural gas line when the ball
valve failed and the released pressure threw him into
a piece of iron and another piece of iron fell on him
• SIC 0782 – A 64 year old employee was found
slumped over and pinned by a running mower

• SIC 5399 – A 58 year old employee buffing floors
stopped to take a drink of water and fell backwards
from a standing position and struck his head on the
floor. He continued working his shift and went to the
local hospital after his shift. He was then transported
to a Houston hospital and died 1-1/2 weeks later
• SIC 3559 – A 38 year old supervisor was standing
next to a 180°C lithium ion battery being prepared to
be sent out to the oil field. To prepare the battery it
was heated to 160°C by a technician to depassivate
and test voltage when it exploded

• SIC 2411 – A 51 year old employee was part of a
crew assigned to fell trees with a chainsaw. The
owner operating a vehicle loader saw a tree fall about
200 yards away and no other trees falling for about an
hour. An employee was sent to search for him and it
was reported he couldn’t be found. A skidder was
used to move the 75’ felled tree and he was found
underneath it
• SIC 3533 – A 51 year old employee working 15-20’
high on aerial lift detaching rigging used to lift a rig
derrick onto a stand. When the stand failed the derrick
hit the aerial lift basket ejecting him

• SIC 3499 – A 30 year old employee using a portable
electric grinder and work light to inspect top portion of
a metal skid elevated on metal stands in the spray
room. The tools were plugged into a heavy duty cord
and pigtail to an explosion proof outlet. He hung the
light on a beam and received a slight shock when the
welding machine started. A spark was noticed coming
from the hook. He picked up the light by the metal
cage and held it to his chest while putting tape on it.
He was drenched in sweat and another employee
noticed he was being shocked and the extension cord
was pulled out of the socket. He later died.

• SIC 3999 – A 55 year old employee on a crew
converting 3,000 lb fuel tank into a water tank. The
tank was being raised using a chain rigged from a
angle hook on top of the forklift to support the tank as
the crew were trying to connect a pipe to the under
side. Angle hook weld broke and the tank fell on him
• SIC 1389 – A 57 year old employee on a crew
rotating the outlet valves of a desander suspended
from the forks of a forklift. He was under the desander
attempting to loosen bolts on a valve when the load
shifted and fell from the forklift crushing him

• SIC 0782 – A 33 year old landscaper had been
mowing grass for about 20 minutes at the second
job site of the day when he collapsed. He was given
cold water, placed in the shade, 911 called. He was
taken to the hospital and later died of hyperthermia
• SIC 0782 – A 49 year old tractor operator towing a
brush hog was clearing grass around power and
telephone poles when he fell off the tractor which
came to rest on top of him causing asphyxiation
• SIC 3731 – A 41 year old welder in a barge cutting
away a bottom plate with cutting torch when a fire
erupted. He and his 31 year old foreman who
attempted rescue died as a result of the fire

• SIC 4741 – A 31 year old rail car cleaner entered a
railcar to retrieve a gasket. The rail car had not been
washed or permitted for entry and last contained
olefin sulfide and the MSDS indicates it contains
hydrogen sulfide. He went down the ladder and
climbed back up to the top of the rail car and
attempted to get out but fell back into the rail car
• SIC 7549 – A 37 year old wrecker driver unhooking
a disabled truck when he was found pinned between
the wrecker and the running truck

• SIC 4231 – A 27 year old tank wash lead man was
cleaning interior and exterior of tank trucks. The tank
man way was opened a compressed air hose
attached to the rear washout coupling to ventilate
the tank. He was found inside unresponsive. The
tank previously contained a urethane based product
containing a mixture of 9+ compounds. The tank
had previously been off loaded using nitrogen. Due
to the chemical characteristics and the nitrogen it is
believed that the oxygen had been displaced and he
became unconscious as he peered inside the
open man way and fell in

• SIC 7389 – A 28 year old employee was on his
second day of work and conducting his first dive
watched another employee vacuum silt from a 32’
deep water tank for about 10 minutes. The vacuum
hose was then given to him and the other diver left
after 5 minutes. That employee took off his diving
gear and was holding the tie off rope when it went
slack. All the rope pulled in and so the employee
dove in and found him on bottom of tank with mask
off. The deceased air tank was checked and found
to be empty and the pony tank was empty as well.

• SIC 4491 – A 45 year old maintenance worker
was working on a chassis trailer attempting to
release the brakes which had seized up. One
employee was in the yard truck driver seat
connected to the chassis trailer while the other
employee used tools on the brakes to free the
seized pads from the drums. Driver moved
chassis forward to see if brakes had released.
The employee working on the brakes was in the
rear axle drive path and the movement forward
caused fatal crushing injuries

Houston FY11 Significant Cases
• Igloo Products - $113,500 - Complaint
– Alleged 14 serious, two repeat, and four
other- than-serious
– Citations related to walking working surfaces
and platforms, railings, PPE assessment,
providing eye protection, eyewash and
showers, machine guarding, electrical panels,
lokout/tagout, power tools, and labeling
electrical equipment

• US Minerals - $273,000 – SVEP
– Alleged three willful and 25 serious violations
– Citations related to fall protection on
platforms, emergency stops on conveyors,
floor covers, damaged ladders, securing
cylinders, fire extinguishers, and
lockout/tagout procedures,

• Pasadena Refining Services - $115,650 –
Refinery NEP
– Alleged 21 serious violations
– Citations related to scaffolds, piping support,
valve controls, annual confined space audits,
guard rails, and up to date operating
procedures

• Tex-Tube – $124,740 – SST
– Alleged twelve serious, four repeat, and ten
other-than-serious
– Citations related to floor openings, periodic
testing of LOTO procedures, seatbelts,
exposed electrical on cranes, LOTO
procedures, guarding electrical, OSHA forms

• O’Brien Wire Products - $159,390 – F-Up
– Alleged five serious, twp repeat, and three
other-than-serious
– Citations related to damaged ladders, crane
hook, noise survey, machine guarding, door
on restroom, and hand washing facilities

• Schumacher Co - $166,500 – Referral
– Alleged 31 serious and two other-than-serious
violations
– Citations relating to PPE, guarding, fall
protection/rails, LOTO procedures, cleaning
procedures for hexavalent chromium, fit
testing, and hexavalent chromium exposure
monitoring

• Texas Boat & Barge - $221,200 – Fatality
– Alleged 1 willful and 39 Serious violations
– Citations related to failure to conduct air
monitoring prior to entry to confined and
enclosed spaces, fall protection around barge
and manholes, securing of cylinders, proper
electrical wiring, labeling of circuit breakers,
respirator fit testing, inspection of oxygen
acetylene hoses, and fire safety plan

• Duna USA - $136,800 – Complaint
– Alleged 29 serious and 3 other-than-serious
– Citations related to failure to not use hearing
protection, develop an emergency action plan,
develop and use LOTO procedures, initial
monitoring for methylene chloride, and PSM.
Other than serious items related to failure to
make exit doors and locating of fire
extinguishers

• Enterprise Products - $160,000 – Complaint
– Alleged 29 serious and three other than serious
violations
– Citations related to fall protection, access to
platforms, LOTO procedures, respiratory
protection, PIT training, chemical storage,
inspecting breathing air, and respirator change
schedule

Prepared by the Directorate of Enforcement Programs
October 12, 2011
FY11 (Oct 1, 2010 – Sep 30, 2011)
Federal OSHA Inspection Data

FY07 – FY11 Inspections Conducted
39,324
38,667 39,004 40,993 40,792
0
10,000
20,000
30,000
40,000
50,000
FY07 FY08 FY09 FY10 FY11

FY07 – FY11 % Programmed vs. %
Unprogrammed
59%
41%
60%
40%
62%
38%
60%
40%
58%
42%
0%
20%
40%
60%
80%
100%
Programmed Unprogrammed

FY07 – FY11 % Complaint Inspections
18% 17% 17% 20% 21%
0%
20%
40%
60%
80%
100%

FY07 – FY11 % Follow-Up Inspections
2% 2%
3% 3% 3%
0%
5%
10%
15%
20%

FY07 – FY11% Inspections In-Compliance
26% 23% 25% 23% 23%
0%
20%
40%
60%
80%
100%

FY07 – FY11 Total Violations Issued
88,846 87,210 87,663
96,742
82,816
0
20,000
40,000
60,000
80,000
100,000
120,000

FY07 – FY11 % Tot Violations Issued Serious
76% 77% 77% 77%
73%
0%
20%
40%
60%
80%
100%

FY07 – FY11 % Tot Violations Issued As
S, W, R, & Unclass
79% 81% 81% 82%
78%
0%
20%
40%
60%
80%
100%

FY07 – FY11 % NIC Inspections With Only
Other-Than-Serious Violations Cited
11% 10% 10% 10% 11%
0%
20%
40%
60%
80%
100%

FY07 – FY11 % Inspections w Violations
Contested
7% 7% 7% 8% 8%
0%
20%
40%
60%
80%
100%

FY07 – FY11 Average Current Penalty Per
Serious Violation
$918 $998 $970 $1,053
$2,223
$0
$500
$1,000
$1,500
$2,000
$2,500
$3,000

FY07 – FY11 % Construction Inspections
59% 60% 61% 60%
56%
0%
20%
40%
60%
80%
100%

FY07 – FY11 Egregious Cases
3
5
4
20
14
0
5
10
15
20
25
30

FY07 – FY11 Average Hours Per Safety
Inspection
18 18 18 19 19
0
10
20
30

FY07 – FY11 Average Hours Per Health
Inspection
32 32
30
33 32
0
10
20
30
40
50

FY07 – FY11 Fatality Investigations
1,043
936
797 804
720
0
250
500
750
1,000
1,250

FY11 Top 10 Most Cited Standards (GI)
1. Hazard
Communication
2. Respiratory
Protection
3. Lockout/Tagout
4. Electrical, Wiring
Methods
5. Powered Industrial
Trucks
6. Electrical, General
Requirements
7. Machine Guarding
8. Recordkeeping
9. Personal Protective
Equipment
10.Mechanical Power
Transmission
Apparatus

FY11 Top 10 Most Cited Standards (Cnst)
1. Fall Protection
2. Scaffolding
3. Ladders
4. Fall Protection,
Training
Requirements
5. Hazard
Communication
6. Head Protection
7. General Safety &
Health Provisions
8. Aerial Lifts
9. Eye & Face
Protection
10.Specific Excavation
Requirements

Where is OSHA Located?
Houston North Area Office:
Jim Shelton
507 N. Sam Houston Pkwy E.
Ste. 400
Houston, TX 77060
281-591-2438
shelton.james@dol.gov

Disclaimer
• This information has been developed by an OSHA Compliance Assistance
Specialist and is intended to assist employers, workers, and others as they
strive to improve workplace health and safety. While we attempt to
thoroughly address specific topics [or hazards], it is not possible to include
discussion of everything necessary to ensure a healthy and safe working
environment in a presentation of this nature. Thus, this information must be
understood as a tool for addressing workplace hazards, rather than an
exhaustive statement of an employer’s legal obligations, which are defined
by statute, regulations, and standards. Likewise, to the extent that this
information references practices or procedures that may enhance health or
safety, but which are not required by a statute, regulation, or standard, it
cannot, and does not, create additional legal obligations. Finally, over time,
OSHA may modify rules and interpretations in light of new technology,
information, or circumstances; to keep apprised of such developments, or to
review information on a wide range of occupational safety and health topics,
you can visit OSHA’s website at www.osha.gov.

OSHA Houston Area Overview and Statistics 2011

OSHA Houston Area Overview and Statistics 2011

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