Safety Lines

The Newsletter of Minnesota OSHA

Number 50 Winter 2006
http://www.doli.state.mn.us

Truck-bed-lining industry no breath of fresh air

By Amy Gallagher, Industrial Hygienist

The urethane spray-on truck-bed-liner industry has been growing

rapidly and it is estimated that more than 2,000 businesses are in
operation in the United States. Increasing knowledge of health
hazards and a 2003 fatality in Michigan related to spraying truck-
bed-liners has initiated concern among occupational safety and
health agencies. The major hazard in the industry is exposure to
isocyanates in the product that is used. Established health risks of
isocyanates include occupational asthma, which caused the death
of the bed-liner applicator in Michigan, despite precautions taken
such as respirator use and ventilation. The majority of exposures
with the bed liners occur when the product is applied with a spray
gun, releasing isocyanate vapors and aerosols into the ambient air Photo from www.cdc.gov
surrounding workers.

Isocyanate hazards
Concerns regarding isocyanate exposures are well substantiated. Isocyanates have been documented
to be strong irritants, with exposures causing burning and redness to the eyes, and irritation to the skin
and respiratory tract. The greatest concern with isocyanates is that the chemical can induce asthma in
workers. Inhaled isocyanates can trigger the airways to narrow, making it difficult to breathe, which
Bed-liners continues ...

In the wake of Hurricanes Katrina and Rita:

– Minnesota OSHA employee assists Red Cross in hurricane aftermath–
By Erny Mattila, Safety Grant Program Coordinator

Editor's note: Erny Mattila, Minnesota OSHA Workplace Safety Consultation, has volunteered with the Red Cross as a
Disaster Relief Team member since 1994. Typically, he responds to tornadoes and residential fires throughout the Twin Cities
metropolitan area – at all hours – to assist victims with first aid and vouchers, and to conduct damage assessment so victims
can settle with the insurance companies. This is his account – and his photos – of his recent efforts in the Gulf Coast.

On Sept. 26, I flew from Minneapolis to Dallas and then to Austin, Texas, where I was processed-in as
a Red Cross Damage Assessment Team leader due to my previous experience. The Damage Assessment
Team cannot condemn buildings or hand out food, water or clothing; we simply make note of the amount
of damage to a certain property so the Red Cross, Federal Emergency Management Agency (FEMA) and
the insurance companies can refer to our reports when property owners make claims for assistance.
Hurricanes Katrina, Rita to page 6
 Bed-liners continued ...
ultimately was the cause of the Michigan fatality. Isocyanates
are dangerous because they may sensitize workers, so that
asthmatic reactions may be elicited upon subsequent exposures
to isocyanates, even when concentrations are below established
safe limits. Recent studies conducted on this isocyanate-induced
asthma have indicated these respiratory symptoms can persist
for years, in spite of discontinued exposure, resulting in workers
Graphic from www.ccar-greenlink.org
succumbing to lifelong effects. With such devastating effects to
worker health, it is important all appropriate measures be taken to reduce exposures.

MNOSHA isocyanate initiative

As a result of the Michigan fatality and increasing hazards reported regarding isocyanates, the Minnesota
Occupational Safety and Health Administration (MNOSHA) developed and implemented a local-emphasis
isocyanate initiative to conduct inspections of facilities involved in truck-bed-liner operations.

Inspections were conducted from April 2004 through June 2005; the results of the initiative indicated
67 percent of the companies inspected were found to have exposures to isocyanates, specifically
methylene bisphenyl isocyanate (MDI), exceeding the OSHA permissible exposure limit (PEL) ceiling
of 0.02 parts per million (ppm). Overexposures averaged approximately seven times in excess of the
established limits and ranged from 1.2 to 26.5 times the PEL. Violations found at the majority of the
companies included citations for inadequate respiratory protection (1910.134), lack of right-to-know
training (5206.0700) and deficiencies in engineering controls to prevent overexposures to isocyanates
(1910.1000). The high instances of overexposures and noncompliance indicate the need to improve
conditions at businesses involved in spraying truck-bed-liners.

Cases of special concern regarding isocyanate overexposure highlighted by MNOSHA included the
following situations.
• An assistant was overexposed by 12.5 times the PEL in addition to the sprayer. The assistant stood
directly by the exhaust fan that was drawing MDI contaminated air to outside of the spray area.
• An inspection indicated overexposure of 1.2 times the PEL at the fresh-air intake for the supplied
air respirator.
• Another inspection yielded a significant overexposure of 26.5 times the PEL.

Methods for reducing exposure

When applying spray-on truck-bed-liners, employees are at risk for unsafe exposures to isocyanates.
Measures such as engineering controls, chemical hazard training, work practices and personal protective
equipment must be taken to ensure the health and safety of all workers involved with the bed-liner
application process.

Engineering controls
One of the most effective measures to minimize exposure to isocyanates is the use of an enclosed
ventilated system, which should be the primary means of protection. Commercially designed spray
booths are available and can be effective when properly installed. It is important that the performance of
the ventilation of the system is evaluated to ensure the capture and containment of the isocyanate vapors
away from workers during the spraying process. Changing the filters for the ventilation equipment
frequently and conducting periodic maintenance on the system will help to further ensure reductions in
airborne levels of isocyanates.
Bed-liners continues ...
Safety Lines  Winter 2006
Bed-liners continued ...
Chemical hazard training, employee right-to-know
On many occasions, workers are not trained about the hazards associated with
the chemicals they are working with. In Minnesota, this training is required by
the Employee Right-To-Know Act. Employers must supply information about
the health hazards associated with isocyanates and spraying truck-bed-liners,
so workers will be able to detect early symptoms of overexposure and receive
treatment before health effects progress. Also, employers must provide employees
with material safety data sheets (MSDSs) about bed-liner materials and safety
information provided by the manufacturer to further ensure the safe use of the
Photo from
product. allegrosafety.com

Work practices
How workers apply the bed liner can also influence the amount of exposure to isocyanates. While
spraying, the following practices can be used.
• Make sure workers do not stand in the flow of contaminated air produced by the spray gun to the
exhaust ventilation system.
• Workers should refrain from being in the bed of the truck while spraying. Standing by the side of
the truck bed is preferred, to reduce exposure to the spray.
• If possible, an application technique that uses lower temperatures, less pressure and lower amounts
of aerosols can be used to reduce isocyanate exposures.

Personal protective equipment

Although personal protective equipment (PPE) is not to be used as a primary means of protection against
isocyanate exposures, it can help further reduce exposures to safe levels when combined with effective
engineering controls. When applying a bed liner, risk for overexposure to isocyanates is high and use
of a full-face, supplied air respirator (SAR) is the best means to protect the well-being of workers. Air
purifying respirators can be used, but a strict cartridge change-out schedule must be followed to ensure
proper use of the respirator. Hazards can arise with the use of air purifying
respirators when change-out schedules are not followed. The cartridges to purify
the air can become saturated with MDI and “breakthrough” can occur where
MDI can pass through the cartridges. Workers wearing the respirator will then be
exposed to MDI and may not know it, because MDI has poor warning properties
(for example, odor and irritation) that cannot be detected until excessive levels of
MDI are present.

The following practices regarding respirators will aid in proper protective

function of the PPE.
• Conduct fit tests to ensure a proper seal is made with the skin and the face piece,
and that the respirator is providing an adequate barrier from contaminants.
• Make sure respirators are stored correctly in a clean location away from
contaminants and that maintenance is conducted to ensure the function of the
respirator.
• If using a supplied air respirator, keep the supplied air intake outside of the
spray area to ensure fresh air is being provided to the worker and not harmful
contaminants.
• Ensure medical evaluations for all workers wearing respirators are conducted
to make sure the employees can safely and effectively be protected by the
respirators. Bed-liners continues ...
Safety Lines  Winter 2006
Bed-liners continued ...
Also, it is important to use PPE to cover all skin that may be exposed during the bed-liner application.
Skin contact with MDI not only can cause irritation, but has been found to sensitize workers to further
exposures and can even elicit an asthma attack. The following PPE should be used to avoid exposures
to the skin: chemical resistant coveralls or suit; gloves, such as Nitrile or other gloves rated for use with
MDI; covering on head and neck, such as a hood on a chemical suit; face protection; and protection on
feet, such as chemical resistant boots and coverings.

More information
More information about isocyanate use and spray-on truck-bed-liners can be accessed from
the following organizations.
• National Institute for Occupational Safety and Health (NIOSH)
– www.cdc.gov/niosh/topics/isocyanates
− Preventing asthma and death from diisocyanate exposures (1996) online at
www.cdc.gov/niosh/asthma.html

• Occupational Safety and Health Administration (OSHA)

− www.osha.gov/SLTC/isocyanates/index.htm

• Washington Industrial Safety and Health Act (WISHA)

− Spray-on urethane truck bed linings and isocyanate exposures (March 2003) online at
www.LNI.wa.gov/wisha/hazalerts/March2003HazardAlert_Final_.pdf
− MDI exposure for spray-on truck bed lining by Lofgren, D., Wally, T., Peters, P., and Weis, M.
(2003) in Applied and Environmental Hygiene, 18; pages 772-779

• Alliance for the Polyurethanes Industry (API)

– www.polyurethane.org

• Michigan State University Reports

− Michigan fatality and control evaluation (MIFACE) investigation #03MI018 (December 2003)
online at www.chm.msu.edu/oem/miface/03mi018.pdf

Nominations for DLI safety award recipient due March 1

The Minnesota Department of Labor and Industry (DLI) seeks to honor a safety or
health professional who is an example of safety excellence, with the annual Arthur E.
McCauley Jr., Minnesota Occupational Safety and Health Leadership Award.

The award was named for former Minnesota Safety Council Member Arthur E. McCauley
Jr., whose work as a safety professional encompassed the attributes of this award.
McCauley was regarded for his work as a member of the Minnesota Safety Council
and the Minnesota Occupational Safety and Health Advisory Council. He was known
for his dedication and tireless efforts to improve the safety and health of Minnesota's
workplaces.
Arthur E. McCauley, Jr.

Complete information and the nomination form are online at www.doli.state.mn.us/mccauley.html. Interested
parties may also contact Susan Boone at (651) 284-5018 or at susan.boone @state.mn.us for details.

Safety Lines  Winter 2006

 New crane-operator regulations — an overview
By Tyrone Taylor, Construction Supervisor

Legislation was enacted in Minnesota May 24, 2005, that

requires the certification and regulation of crane operators. This
is an overview of the new regulation, which takes effect July
1, 2007. According to the new law, no individual may operate
a crane, with the lifting capacity of five tons or more, on a
construction site unless that person has a valid crane-operator
certificate. The certificate must be issued by a nationally
recognized and accredited certification program.

The new regulation applies to all wire rope-over-sheave mobile

cranes and mobile tower cranes. The standard does not apply
to track and automotive jacks, railway or automobile wrecking
cranes, shipboard cranes, shipboard cargo handling equipment,
well drilling derricks, skip hoists, mine hoists, truck body
hoists, car or barge pullers, conveyors or excavating equipment
when not used as a lifting crane.

Operators of cranes shall provide proof of certification upon

request by an investigator. Individual certification may be
received from the National Commission for the Certification
of Crane Operators (NCCCO) or another certifying entity that
has been accredited by the National Commission for Certifying
Agencies. The regulation requires operators to renew their
certification every five years.

The regulation will not apply to:

• a crane operator trainee or apprentice under the direct
supervision of the holder of a valid crane operator
certificate;
• workers directly employed by class 1or 2 railroads, who have been qualified by the employing
railroad as a crane operator, while working on property owned, leased or controlled by the
employing railroad;
• workers employed by or performing work for a public utility, rural electric cooperative,
municipality, telephone company or industrial manufacturing plant;
• workers subject to inspection and regulation under the Mine Safety and Health Act;
• workers engaged in boating, fishing, agriculture or arboriculture;
• workers who are members of or performing work for a uniform service or the United States
Merchant Marines;
• people operating cranes for personal use on property owned or leased by that person; and
• people operating cranes in emergency situations.

Companies are urged to start the certification process early to avoid any major push when the July
1, 2007, deadline draws near. Currently, there are 12 other states that have certification or licensing
requirements.
Safety Lines  Winter 2006
Hurricanes Katrina, Rita from page 1
Processing-in took two days of paperwork,
standing in lines, having physicals and waiting
to be approved by the Red Cross officials to
serve in the field. After I was processed-in, I was
assigned a Red Cross vehicle and a cell phone.
I was then sent to the Houston Red Cross office
where I spent another two days waiting to be
assigned to one of 30 teams. These first few days
were filled with disorganization, dysfunction and
miscommunication: a beast that would rear its
ugly head often during my deployment. However,
aside from the organizational shortcomings, the
individual workers and volunteers were very
nice and very supportive.

I was finally assigned a team member and we were deployed north to Texarkana, Texas, to check on damage
reportedly caused by one of the more than 50 tornadoes spawned by Hurricane Rita as it followed the Texas-
Louisiana border north to Arkansas. The storm damage appeared to be caused by a severe thunderstorm
and not a tornado, because the structural damage was minor and only a few tree branches and power lines
were down. We phoned in our findings and then began looking for housing. However, housing was hard
to find, because Hurricane Rita and Katrina evacuees occupied most of the hotels, motels and shelters in
Texas. We lucked out when a tree contractor canceled a reservation at a local "mom and pop" motel. This
was a pattern that repeated itself every night that we were on the road.

The next day, I was deployed to Longview,

Texas, where another tornado had reportedly
touched down. I found some major structural
damage and, again, trees and power lines
were down. However, this time the damage
was significant and followed a wide path that
skipped from block to block and then ended, as
if a funnel cloud had touched down, skipped
and lifted up.

While in Longview, I checked in with the local

authorities and gave them my cell phone number.
That night, a 35-unit apartment building collapsed. It had been inspected and cleared for occupancy by the
local authorities only a few days earlier and was occupied by local residents and hurricane evacuees. The
local first-responders contacted me and I arrived on the scene at midnight. The local fire department, police
department and emergency medical technicians (EMTs) were already taking people out of the building,
treating people in the parking lot and loading others into ambulances.

Fortunately, only 11 units were involved and most of the injuries were from people rushing down the stairs
and falling. A young, single mother was sitting on the grass next to the parking lot with a blanket around
her. I approached her and asked if I could be of help. She was crying and said she had lost everything in
Port Arthur, Texas, and now her only child, a five-year-old girl, was severely injured when she was trampled
in the staircase. I'll never forget her words, "I just can’t lose her too." EMTs helped her to an ambulance,
Hurricanes Katrina, Rita to page 7
Safety Lines  Winter 2006
Hurricanes Katrina, Rita from page 6
where she and her daughter were whisked away.
I completed my damage assessment report and
left the site.

Later that morning, I checked in at the fire

department to tell them my reports were
completed and that I was leaving. I inquired
about the status of the injured people and was
told they had just gotten a call from the hospital
and that the little girl had died. It was a tough
pill to swallow as I drove to my next assignment
in Marshall, Texas. Over the next few days, my
assessment of both Marshall and Tyler, Texas,
found each community to have localized tornado damage similar to Longview. Fortunately, there were no
fatalities.

The Red Cross then deployed me to Shreveport, La., and areas south, to assess the damage caused about
three weeks earlier by Hurricane Katrina. The wind damage there became more widespread and flood
damage became more apparent as I traveled farther south. The number of trees that were down in the rural
areas was significant. I then headed back to Houston to turn in my reports and was deployed to Beaumont,
Texas.

The Ford Arena in Beaumont was set up as the main headquarters for the Red Cross, National Guard and
local EMTs. Hundreds of staff members and volunteers took shelter there, so the main arena floor and two
adjacent conference center floors were filled with cots, sleeping bags and tents. Also, hundreds of Red
Cross, National Guard and local EMT vehicles were parked outside the arena in marked off areas, ready to
respond. The Ford Arena also served as the main
shelter for Disaster Assistance dogs. Some of the
dogs were trained as search and rescue dogs and
cadaver dogs, and spent most of the day out in
the field. Others spent the day in the building
serving as great stress relievers, especially for
those of us who had left pets at home.

In Beaumont and Port Arthur, the power of

Hurricane Rita and the devastation it left behind
became apparent. Damage was no longer
sporadic, because now it encompassed five
entire counties. For miles and miles, mature trees were just snapped in half, roofs were gone, houses were
gone and cars were crushed. People who had not evacuated were either staying in their damaged homes,
in their neighborhood church or were just wandering the streets. I came upon a church where people had
been sleeping on pews. The minister was exhausted and so were the church funds. I called the Red Cross
and it sent out a Family Services Team to write vouchers for clothing and to bring them food and water.

People were cut off from the rest of the world. There was no electricity, no communication, no food and
no water. However, they had plenty of 100-degree days with high humidity, mosquitoes, rodents and more
than their fair share of fear, frustration and anger. People would rush out from their neighborhoods when
Hurricanes Katrina, Rita to page 8
Safety Lines  Winter 2006
Hurricanes Katrina, Rita from page 7
they saw my car, to see if help was on the way. It was hard to tell them I was only doing damage assessment
and that I did not have water or food. I could assure them help was on the way, but it was hard to drive
away and leave them there.

The nights in Beaumont and Port Arthur were eerie: no building lights, streetlights or traffic signals; nothing
was moving and there were very few noises, other than an occasional speeding emergency vehicle with its
siren screaming and red lights flashing.

Pets, mostly dogs, were roaming the streets during the day, either alone or in packs. We picked up the first
dog we saw and brought her to the local Humane Society. We were disappointed to see the building was
abandoned: the front door was open, the cages were open and bags of food had been piled up in the front
yard. While there, we saw a person drive by and throw a dog out the car window; the dog chased the car
for a block and then wandered back to the Humane Society building looking lost. We tried to help as many
animals as we came across, but unfortunately, our efforts were only temporary. The heat, lack of water and
shock all took its toll on the animals.

As the teams approached the end of their deployment, the Red Cross determined that the Damage Assessment
Team duties were completed and no further assessments were needed. Some team members stayed to help
with logistics, the rest of us had to return to our jobs and were processed-out to make room for more Family
Services Team workers.

I flew home out of Houston. Appropriately, the plane flew to the southwest over Beaumont before turning
north toward Minnesota. I looked out the plane window at some of the same neighborhoods and towns I
had assessed, and I felt for the residents and responders still down there dealing with the aftermath of this
disaster. I was finally going home, but I knew I would not be the same.

Occupational Safety and Health Advisory Council 2006

The Occupational Safety and Health Advisory Council was created in 1973 under the statutory
authority of Minnesota Statutes §182.656 to advise the department in carrying out the purposes
of M.S. §182 and other Occupational Safety and Health Administration statutes.

The council consists of 12 members appointed by the Minnesota Department of Labor and
Industry commissioner. Council members include three representatives from management, three
representatives from labor, three representatives of occupational safety and health professions,
and three representatives from the general public.

Meetings are quarterly, scheduled for Dec. 2, 2005, and March 3, June 16, Sept. 15 and Dec. 1 in
2006. The advisory council meets from 10 a.m. to noon, in the Minnesota Room at the Minnesota
Department of Labor and Industry, 443 Lafayette Road N., St. Paul, MN.

E-mail Susan Boone at susan.boone@state.mn.us or call her at (651) 284-5018 for further
information about the OSH Advisory Council meetings.

Safety Lines  Winter 2006

Former Minnesota OSHA leader Terry Mueller retires
By James Krueger, OMT Director

A crowd of people packed the Minnesota Room at the Department of Labor

and Industry (DLI) in October for the retirement party in honor of former
MNOSHA OSHA Management Team (OMT) Director Terry Mueller – a
30-year-employee of DLI.

In his first eight years with MNOSHA, Mueller was a safety investigator
and a senior safety investigator. During that time, he developed specialties
in foundries and grain elevators. During the next 10 years, he served as a
supervisor of a unit within MNOSHA. The following nine years were spent
as an OMT director for construction and general industry within the Twin
Cities metropolitan area.
Terry Mueller
During Mueller's time as a director and supervisor, he headed up the Ergonomics Team, which
performed inspections throughout the state and engaged in several creative outreach efforts. In addition,
he consulted throughout the state as an expert in the areas of grain elevator and foundry inspections. As
OMT director, Mueller was instrumental in the development of the High Visibility Personal Protective
Equipment standard and the Operation of Mobile Earth-Moving Equipment standard (Minnesota Rules
5205.0030 and 5207.0100) that enable employees to be visible and cautious when working with or
adjacent to motor vehicles and heavy construction equipment.

Mueller wrapped up his DLI career with three years as DLI's Workers' Compensation Division's
Compliance Services director.

Workplace Safety Consultation inks print group alliance

Minnesota OSHA Workplace Safety Consultation

(WSC) signed an Alliance agreement in October
with Print Industry of Minnesota.

WSC and its allies work together to reach out to,

educate and lead Minnesota employers and their
employees in improving and advancing workplace
safety and health.

Through this program, organizations will:

• build trusting, cooperative relationships with
MNOSHA;
• network with others committed to workplace
safety and health; and
• leverage resources to maximize worker safety
Print Industry of Minnesota President David Radziej and DLI
Assistant Commissioner Roslyn Wade sign the Alliance agreement and health protection.
while Paul Gutkowski, PIM safety and environmental services
director, and MNOSHA Workplace Safety Consultation Director For more information, visit www.doli.state.mn.us/
James Collins look on. alliances.html.
Safety Lines  Winter 2006
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Newly hired occupational safety and health

investigators (OSHIs) are required to have a
minimum of a bachelor's degree in a field related
to occupational safety and health, such as
industrial safety, environmental health, industrial
hygiene or engineering. Many staff members have
master's degrees in these areas. Work experience
is, of course, preferred as well. Some individuals
are also considered if they possess a bachelor's
degree in unrelated subjects, but have extensive
work experience in occupational safety and health.
After being hired, the new investigators participate
in a three-phase orientation and training program.
Initial orientation is generally completed within
one week of the start date and is similar to new
employee orientation nearly everywhere. Staff
members receive training about state human
resource policies and procedures, are issued
personal protective and inspection equipment,
undergo medical evaluation, and receive initial
safety and health training.
The next two months are dedicated to initial
investigator training. Here, the investigator learns
about MNOSHA inspection procedures, penalty
calculation and report preparation, and initial
hazard recognition and industrial hygiene
standards. Most of this training is conducted by
MNOSHA training officers and lead investigators,
although some of it is computer-based or assisted.
During this time, the new investigators begin to
accompany experienced OSHIs into the field. They
begin by simply observing the inspection process,
gradually becoming more involved and taking on
more responsibility.
During the first year, the new OSHIs are provided
with training about the enforcement of specific
standards, such as Employee Right-To-Know,
Safety Lines 10 Winter 2006
scaffolding and ergonomics. These classes, or
standard learning units, are presented by the
MNOSHA training officers and senior
investigative staff members.
The MNOSHA Strategic Plan states the unit will
“conduct a comprehensive workskill assessment
and generate a workforce development and
retention plan.” A team, consisting of members
from the OSHA Management Team (OMT) and
MNOSHA Training and Outreach, was assigned to
perform the assessment.
The team developed a list of three skill areas: soft
skills, hard skills and technical skills. The soft
skills include human resource development issues,
such as writing ability, interpersonal
communication, problem-solving and time
management. Knowledge of occupational safety
and health standards and practices constitute the
hard skills, which vary by discipline, such as
industrial hygiene, general industry safety and
construction safety. Technical skills refer to both
field instrumentation and computer equipment.
These skill sets were further divided into basic, or
core, requirements and advanced requirements.
Investigators are expected to demonstrate
proficiency in each of the core skills in their area
of expertise before attending any advanced or
cross training. MNOSHA relies on a wide range of
training tools and providers. Soft skills training is
made available to staff members primarily through
electronic media, such as DVDs or CD-ROM
programs. Short courses can be used to further
augment the learning process. Technical skills are
mainly acquired through on-the-job training.
However, MNOSHA puts the greatest amount of
its training resources into the hard skills arena.
The primary source of hard skills training, whether
core or advanced, is provided by the federal OSHA
Technical Institute (OTI), located in Arlington
Heights, Ill. There, state and federal OSHA staff
members gather to get specialized training about
occupational safety and health issues and
enforcement policies, and to network with their
peers in other states. Courses offered by OTI cover
a wide variety of topics, including: machine
guarding, electrical hazards, fall arrest systems,
excavation, industrial noise and toxicology.
MNOSHA is fortunate, because OTI usually
presents two classes each year for staff members
here in Minnesota. Courses conducted in the state
within the past two years include:
• OSHA 2015 Hazardous Materials;
• OSHA 3100 Applied Spray Finishing and
Coating Principles;
A perennial hazard: carbon monoxide
By Diane Amell, Training Officer
Minnesota OSHA (MNOSHA)
investigators continue to detect
hazardous levels of carbon monoxide (CO) in
workplaces across the state. While employee
overexposure to CO can occur all year, the
problem increases as the winter weather sets
in. While forklifts are often implicated in the
incidents, MNOSHA investigators have
measured high CO levels from fossil fuel
combustion associated with:
• ceiling-mounted heating units;
• bakery ovens;
• water heaters, including those built into
parts washers;
• freight/luggage tugs;
• outboard motor repair;
• warehouse operations, including
adjoining offices;
Safety Lines 11 Winter 2006
• OSHA 3160 Steel Erection;
• OSHA 1020 Basic Accident Investigation;
and
• OSHA 2074 Fire Protection and Life Safety.
MNOSHA investigators also attend hard skills
training classes conducted by the Great Lakes
Regional OTI Education Center and through
various private companies. MNOSHA's goal is to
have each OSHI participate in at least 40, but no
more than 80, hours of classroom training each
year.
MNOSHA expends a considerable amount of
resources toward staff training. However, by
having well-trained investigators, Minnesota
OSHA will be able to work toward its mission of
making sure “every worker in the state has a safe
and healthful workplace.”
• welding operations;
• inadequate or nonfunctioning ventilation
systems, including insufficient make-up
air as compared to exhaust ventilation;
• concrete mixing and pouring indoors;
and
• temporary heaters on construction sites.
Many of these overexposures have been due to
malfunctioning or improperly maintained
equipment.
MNOSHA has created a fact sheet describing
the different methods for monitoring CO
levels in the workplace, along with the
Minnesota Rules requirements. It is online at
www.doli.state.mn.us/newco.html.
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1-877-47

aLERT
Motor-vehicle safety
Initiative
Each year, traffic-related crashes claim the lives of more workers, both statewide and nationally, than
any other single cause. The purpose of this alert is to heighten public awareness of this often-overlooked
occupational hazard and to provide employers and employees with some tips about how to abate it.

Description of the hazard

In a review of data of a five-year period, the National Institute for Occupational Safety and Health
(NIOSH) found that at least 56 percent of workers killed in traffic crashes were not wearing seat belts.
The leading contributing factors to these crashes included: running off the road or crossing out of the
proper lane, speeding, driver inattention and drivers who were drowsy or fell asleep. Alcohol use by the
driver was involved in 8 percent of the accidents.

Controlling the hazard

The single most important prevention measure from worker death or serious injury is the use of seat
belts. Federal OSHA and the National Highway Transportation Safety Administration (NHTSA) have
actively promoted seat belt usage recently through the "Every belt – every ride" program.

Other precautions employees can take to reduce the likelihood of being involved in traffic accidents
include:
• driving within the speed limit;
• avoiding driving when tired or fatigued; and
• becoming familiar with vehicle maintenance.

NIOSH and OSHA have identified four key areas employers should focus on to reduce crash-related
injuries: policies, fleet management, safety programs and driver performance.

Among the recommended policy components are:

• assigning responsibility and authority to a key management team member for developing and
enforcing the driver safety program;
• enforcing mandatory seat belt use;
• developing work schedules that do not require workers to exceed speed limits, work far beyond
their normal hours, drive during irregular hours or violate regulatory hours of service; and
• not permitting or requiring employees to use cellular phones while driving.

Fleet management issues include establishing a written vehicle maintenance program and providing
employees with vehicles that offer the highest possible levels of occupant protection.
Motor-vehicle safety, continues ...

Safety Lines 12 Winter 2006

Motor-vehicle safety, continued ...
Safety training program content should include:
• recognition and management of fatigue and in-vehicle distractions;
• the importance of safe driving practices both on and off the job; and
• safe operation of any specialized vehicles and equipment.

Driver performance should be gauged by ensuring the employee has a valid driver’s license to operate
the assigned vehicle, checking the employee’s driving record on an initial and periodic basis, and
maintaining records of driving performance.

For more information

Employers and employees with questions or concerns can consult the federal OSHA and NIOSH Motor
Vehicle Safety topics pages (below), or contact MNOSHA Compliance at (651) 284-5050 or toll-free at
1-877-470-6742.
• federal OSHA – www.osha.gov/SLTC/motorvehiclesafety/index.html
• NIOSH – www.cdc.gov/niosh/injury/traumamv.html

For information about the requirements for motor vehicles used off the highway, refer to Minnesota
Statutes 5205.0750 Motorized self-propelled vehicles for general industry and 29 CFR 1926.600-.602
for construction.

Former
Former Sears
Sears Tower
Tower gets
gets aa makeover,
makeover, monthly
monthly WSC
WSC visits
visits
Department of Labor and Indsutry Commissioner
Scott Brener joined Minnesota OSHA Workplace
Safety Consultation (WSC) Sept. 30, 2005, during
one of its monthly on-site visits to the former Sears
building in Minneapolis. The site, now called the
Midtown Exchange, features approximately 730
workers who were nearly finished with a two-million-
square-foot makeover of new and existing structures.
The site is being redeveloped by Ryan Construction
Cos., which invited the consultants on-site.
Pictured at left: DLI
Commissioner Scott Brener
(left) and Rick Peper, senior
project superintendent, Ryan
Construction Cos., discuss the
overall plan for the Midtown
Exchange project at Lake
St. and Chicago Ave. in
Minneapolis.
Pictured at far left: Andy
Smoka (second from right)
and Mike Seliga (right),
Minnesota OSHA Workplace
Safety Consultation, discuss issues with the subcontractor about the
rigging of the suspended scaffold, in particular the proper positioning
of outrigger tiebacks, and training and proper use of fall-protection
equipment. Overall, the consultants noted few issues and complimented
the groups on-site for the ongoing efforts to reduce hazards.

Safety Lines 13 Winter 2006

 Outdoor demonstrations add to
Construction Breakfast seminars
In September, Minnesota OSHA kicked off its new series of
Construction Breakfast seminars. The morning meetings offer a
hearty breakfast, served up with some solid safety information.
This time around, parking lot demonstrations have been added to
the mix.

The safety topic in September was personal fall-arrest systems.

In November, attendees learned about skid steer safety. The next
meeting is Jan. 17; participants will learn the true costs of not
having a real safety program.

For more information, visit www.doli.state.mn.us/brkfst.html or

call (651) 284-5375.

Across the top (l to r): Skid steer safety was presented in the parking lot and in the
meeting room during the Construction Breakfast in November by Steve Kohler,
Frattalone Companies (first and second photo), Merlin Satrom, Ziegler/Cat Equipment
Sales and Linda Brown, Minnesota OSHA.

At left below, Gary Underwood, SALA/DBI, demonstrates personal fall-arrest systems

during the Construction Breakfast in September.

2006 Construction Breakfast schedule

• Jan. 17, 2006 • May 16, 2006

Cost of not having a safety program Tubular welded-frame scaffold safety

• March 21, 2006 • Seminar location

A hands-on AWAIR program that works Minnesota Department of Health, Snelling
Office Park, 1645 Energy Park Drive, St. Paul

Safety Lines 14 Winter 2006

 Four Minnesota worksites achieve MNSHARP status
In recent months, Minnesota OSHA's Workplace
Safety Consultation unit has recognized four
worksites that individually achieved Minnesota
Safety and Health Achievement Recognition
Program (MNSHARP) status.

Started in 1996, MNSHARP recognizes companies

whose managers and employees work together to
develop safety and health programs that go beyond
basic compliance with all of OSHA standards, and
result in immediate and long-term prevention of
job-related injuries and illnesses.
Huisken Meat Company
Key elements of comprehensive safety and health Sauk Rapids, Minn.
programs include: management leadership and
employee involvement; an allocation of resources
to address safety issues; systems that identify and
control workplace hazards; and a plan for employee
safety training and education.

The five worksites were:

• Huisken Meat Company, Sauk Rapids, Minn.
• Anchor Block Company, Zenith Products
Division, Maple Grove, Minn.
• Anchor Block Company, N. St. Paul, Minn.
• D&D Commodities Ltd., Stephen, Minn.

Visit www.doli.state.mn.us/mnsharp.html for more

information or call Workplace Safety Consultation Anchor Block Company, Zenith Products Division
Maple Grove, Minn.
at (651) 284-5060.

D&D Commodities Ltd. Anchor Block Company

Stephen, Minn. N. St. Paul, Minn.
Safety Lines 15 Winter 2006
Minnesota OSHA coordinates national publication
that highlights state-plan safety, health efforts

GRASSROOTS Workplace Protection is an annual publication developed in cooperation

with federal OSHA and the Occupational Safety and Health State Plan Association
(OSHSPA) to highlight areas where OSHA state-plan states are unique from federal
OSHA.

There are 26 state-plan jurisdictions that have been

approved by federal OSHA to run their own occupational
safety and health programs. By law, these states must have
programs that are at least as effective as federal OSHA.

The most recent edition of GRASSROOTS Workplace

Protection describes innovative approaches to workplace
security, customer service, enforcement emphasis in high-risk
workplaces, technology and voluntary compliance that have
been developed by the states. Two new sections highlight
original approaches members have taken in changing the
work environment and advancing technology.

Minnesota's MNOSHA program is specifically mentioned

in sections about: workplace security, strategic plans,
customer services, safety and health programs, site-
specific targeting, significant cases, settlement agreements,
violation approach in cases involving death or serious
injury, state initiatives, technical advances, voluntary
protection programs, partnerships and alliances, and
training and education initiatives.

OSHSPA links the 26 state-plan jurisdictions, federal OSHA and Congress. At meetings
three times a year, state-program representatives share information and discuss common
problems.

The Minnesota Department of Labor and Industry coordinated the GRASSROOTS

publication for federal fiscal-year 2004; it will also coordinate the next edition.
Visit www.osha.gov/fso/osp/oshspa/annualreport.html for current and past editions of
the annual OSHSPA report.
Bureau of Labor Statistics:
Online tools create custom tables
By Brian Zaidman, Research Analyst
Research and Statistics

Two new tools are now available on the U.S. Department of Labor,
Bureau of Labor Statistics, Injuries, Illnesses and Fatalities (IIF) Web
page at www.bls.gov/iif: the "Occupational injuries and illnesses
profiles" tool and the "Incidence rate calculator and comparison" tool.
These tools provide employers and employees with statistics they can
use to benchmark, monitor and improve the safety and health systems in
their workplaces.

The profiles tool allows the user to generate three types of survey results
tables, available for the United States and for 44 states and territories,
including Minnesota:
• case and demographic numbers (Table 1);
• case and demographic incidence rates (Table 2); and
• annual survey summary numbers and rates (Table 3).

Tables 1 and 2 provide information about the characteristics of injured

workers and their injuries for cases with one or more days away from work.
Tables can be created to select cases by industry, occupation, injury type, age,
gender and job tenure. Table 3 provides the complete set of numbers and
incidence rate estimates for each selected industry. Currently, only data about
2003 injuries and illnesses is available.

The tool can be accessed directly at: http://data.bls.gov/GQT/servlet/

InitialPage.

The rate calculator tool allows the user to calculate an establishment’s nonfatal
injury and illness incidence rate(s) per 100 full-time employees for a given
year, provided they have OSHA log data summary numbers available. Four
different incidence rates can be calculated:
• total rate – the total recordable injury and illness cases;
• days away rate – the cases involving days away from work only;
• job transfer/restriction rate – the cases involving job transfer or restricted
work activity only; and
• DART rate – the total cases involving days away from work, days of
restricted work activity and/or job transfer.

The results can be compared to any industry in any available state.

This tool can be accessed directly at: http://data.bls.gov/IIRC.

Safety Lines 17 Winter 2006

 Recordkeeping 101: Part 5
Injury or illness?
By Brian Zaidman, Research Analyst, Research and Statistics

Editor's note: This is the fifth installment of a series about using the OSHA Form 300 and summarizing its results. This
information is directed to people who are new to OSHA recordkeeping activities, to people who might be unfamiliar with the 2002
recordkeeping changes and to people who want to review their recordkeeping practices. This installment deals with classifying
cases as either injuries and illnesses. The prior installments are available at www.doli.state.mn.us/recordkeeping.html.

This installment is about classifying cases as either

injuries or illnesses (OSHA log columns M1
through M6). Previous installments of this series
discussed basic OSHA recordkeeping
requirements; the process for classifying cases as
vs.
either days away from work, job transfer or
restriction, or other recordable cases; counting
days for days-away-from-work cases and cases
with job transfer or restriction; and describing
injury characteristics. fracture and burn. Sprain and strain injuries to
muscles, joints and connective tissues are
The formal title of the OSHA log is “Log of work- classified as injuries when they result from a slip,
related injuries and illnesses.” Employers classify trip, fall or other similar accidents.
each case as either an injury or illness in columns
M1 through M6 (see figure below). Each case Column M2—Skin diseases or disorders
needs to have a check in only one of the columns. Skin diseases or disorders are illnesses involving
There is one column for injuries (M1), four the worker’s skin that are caused by work exposure
columns for specific illness types (M2 through M5) to chemicals, plants or other substances. Some
and one column for any illness not included in the examples are: contact dermatitis, eczema and
other columns (M6). Employers are instructed to rashes caused by primary irritants.
check the injury or illness category that best fits Column M3—Respiratory conditions
the circumstances of the case. Respiratory conditions are illnesses associated
with breathing hazardous biological agents,
Check the "injury" column or choose chemicals, dust, gases, vapors or fumes at work.
one type of illness: Some examples are: pneumonitis, tuberculosis,
(M)
occupational asthma, chronic obstructive
Skin disorder

pulmonary disease (COPD), toxic inhalation

Hearing loss
Respiratory

Poisoning

injury, such as metal fume fever, and chronic

condition

illnesses
All other

obstructive bronchitis.
Injury

(1) (2) (3) (4) (5) (6) Column M4—Poisoning

Poisoning includes disorders evidenced by
abnormal concentrations of toxic substances in
blood, other tissues, other bodily fluids or the breath
Column M1 — Injury that are caused by the ingestion or absorption of
An injury is any wound or damage to the body toxic substances into the body. Some examples are:
resulting from an event in the work environment. poisoning by lead, mercury, cadmium or other
Some common injury types are: cut, abrasion, metals; poisoning by carbon monoxide, hydrogen
Recordkeeping, continues ...
Safety Lines 18 Winter 2006
 Recordkeeping 101: Part 5
sulfide or other gases; poisoning by benzene, carbon
tetrachloride or other organic solvents; poisoning by
insecticide sprays, such as parathion or lead
arsenate; poisoning by other chemicals, such as
formaldehyde, plastics and resins.
Column M5—Hearing loss
Noise-induced hearing loss is defined as a change
in hearing threshold relative to the baseline
audiogram of an average of 10 decibels or more in
either ear at 2,000, 3,000 and 4,000 hertz, and the
employee’s total hearing level is 25 decibels or
more above audiometric zero in the same ear(s).
There is more detailed information about hearing
loss available on the OSHA recordkeeping Web
site at www.osha.gov/recordkeeping/
hearinglossflowchart.pdf.
Column M6—All other occupational illnesses
Use this column only for illnesses that cannot be
classified in one of the other categories. Some
examples of other illnesses are: heatstroke, heat
exhaustion, freezing, frostbite, effects of welding
flash, anthrax and bloodborne pathogenic diseases,
such as AIDS, HIV, hepatitis B and hepatitis C.
If still unsure about the classification, employers
could use the longstanding distinction between
Online resources
Federal OSHA recordkeeping resources
• www.osha.gov/recordkeeping/index.html
MNOSHA recordkeeping resources
• www.doli.state.mn.us/recordkeeping.html
MNOSHA WSC recordkeeping training
• www.doli.state.mn.us/osheven.html
Survey of Occupational Injuries and Illnesses
• www.bls.gov/iif
• www.doli.state.mn.us/dlistats.html
Packet of recordkeeping forms, instructions
• www.osha.gov/recordkeeping/RKforms.html
Booklet: Minnesota OSHA recordkeeping requirement
• www.doli.state.mn.us/pdf/recordkeepingstandard.pdf
Contact MNOSHA
Minnesota OSHA Compliance (MNOSHA)
(651) 284-5050
1-877-470-6742
Workplace Safety Consultation (WSC)
(651) 284-5060
1-800-657-3776
Recordkeeping packet
(651) 284-5042
1-800-342-5354
cases that result from instantaneous events or
exposures in the work environment (injuries) and
all other cases (illnesses).
Regardless of whether a case is considered an
injury or an illness, it is only a recordable case if it
results in death, loss of consciousness, days away
from work, restricted work activity or job transfer,
medical treatment beyond first aid or if it meets
any of the additional criteria (see the first article in
this series). For example, a work-related rash that
can be treated with a nonprescription ointment and
that does not result in any job restrictions or time
away from work is not a recordable case.
Remember to update the log when new
information about an illness or injury becomes
available.
Next
installment:
summarizing
log
entries