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Inspection Detail
Inspection: 310470034 - Rpi Coating, Inc.
Inspection Information - Office: Denver Area Office
Site Address:
Rpi Coating, Inc.
Cabin Creek Hydro Generation Station
Georgetown, CO 80444
Mailing Address:
10114 Shoemaker Avenue, Santa Fe Springs, CA 90670
Union Status: Union
SIC:1721
NAICS: 237310/ Highway, Street, and Bridge Construction
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 03/20/2008
Emphasis: S:Lead, S:Powered Ind Vehicle, N:Lead, S:Electrical, S:Fall From Height
Case Closed: 01/11/2016
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 101574846 | ||
| Referral | 201579117 | Yes |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 25 | 13 | 2 | 40 | ||
| Current Violations | 25 | 2 | 13 | 40 | ||
| Initial Penalty | $66,600 | $778,500 | $0 | $0 | $0 | $845,100 |
| Current Penalty | $25,000 | $0 | $0 | $0 | $75,000 | $100,000 |
| 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 | Serious | 19100023 C01 | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 2. | 01002 | Serious | 19100023 D01 | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 3. | 01003 | Serious | 19100106 D06 IV | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 4. | 01004A | Serious | 19100106 E02 II | 03/21/2008 | 12/19/2011 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 5. | 01004B | Serious | 19100106 E02 III | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 6. | 01005 | Serious | 19100106 E05 I | 03/21/2008 | 12/19/2011 | $1,000 | $2,250 | $0 | 04/14/2008 | F - Formal Settlement | |
| 7. | 01006 | Serious | 19100106 E06 II | 03/21/2008 | 12/19/2011 | $1,000 | $2,250 | $0 | 04/14/2008 | F - Formal Settlement | |
| 8. | 01007 | Serious | 19100134 D01 I | 03/21/2008 | 12/19/2011 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 9. | 01008 | Serious | 19100134 E06 II | 03/21/2008 | 12/19/2012 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 10. | 01009 | Serious | 19100134 H02 I | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 11. | 01010 | Serious | 19100146 C02 | 03/21/2008 | 12/19/2011 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 12. | 01011A | Serious | 19100146 F07 | 03/21/2008 | 12/19/2011 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 13. | 01011B | Serious | 19100146 F13 | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 14. | 01012 | Serious | 19100253 B02 II | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 15. | 01013 | Serious | 19100253 B04 III | 03/21/2008 | 12/19/2011 | $1,000 | $2,250 | $0 | 04/14/2008 | F - Formal Settlement | |
| 16. | 01014 | Serious | 19100303 B08 I | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 17. | 01015 | Serious | 19100303 F02 | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 18. | 01016 | Serious | 19100303 G02 I | 03/21/2008 | 12/19/2011 | $1,000 | $2,250 | $0 | 04/14/2008 | F - Formal Settlement | |
| 19. | 01017 | Serious | 19100304 F01 I | 03/21/2008 | 12/19/2011 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 20. | 01018 | Serious | 19100304 G05 | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 21. | 01019 | Serious | 19100305 A02 X | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 22. | 01020 | Serious | 19100305 A02 XI | 03/21/2008 | 12/19/2011 | $1,000 | $2,250 | $0 | 04/14/2008 | F - Formal Settlement | |
| 23. | 01021 | Serious | 19100305 B01 I | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 24. | 01022 | Serious | 19100305 G02 III | 03/21/2008 | 12/19/2011 | $1,000 | $2,250 | $0 | 04/14/2008 | F - Formal Settlement | |
| 25. | 01023 | Serious | 19100305 J04 V | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 26. | 01024 | Serious | 19100307 C | 03/21/2008 | 12/19/2011 | $1,000 | $1,800 | $0 | 04/14/2008 | F - Formal Settlement | |
| 27. | 01025A | Serious | 19100334 A02 I | 03/21/2008 | 12/19/2011 | $1,000 | $4,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 28. | 01025B | Serious | 19100334 A02 II | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 29. | 02001A | Unclass | 19100106 E02 IVA | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 30. | 02001B | Unclass | 19100106 E02 IVD | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 31. | 02002 | Unclass | 19100106 E05 I | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 32. | 02003 | Unclass | 19100106 E07 IA | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 33. | 02004 | Unclass | 19100106 E07 IA | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 34. | 02005 | Unclass | 19100106 E07 IA | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 35. | 02006 | Unclass | 19100134 I07 | 03/21/2008 | 12/19/2011 | $5,760 | $36,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 36. | 02007A | Unclass | 19100146 C09 II | 03/21/2008 | 12/19/2011 | $5,770 | $49,500 | $0 | 04/14/2008 | F - Formal Settlement | |
| 37. | 02007B | Unclass | 19100146 D11 | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 38. | 02008 | Unclass | 19100146 D04 II | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 39. | 02009 | Unclass | 19100146 D05 I | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 40. | 02010 | Unclass | 19100146 D13 | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 41. | 02011A | Unclass | 19100146 K01 I | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 42. | 02011B | Unclass | 19100146 K01 II | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 43. | 02012 | Unclass | 19100304 G05 | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 44. | 02013 | Unclass | 19101200 H03 III | 03/21/2008 | 12/19/2011 | $5,770 | $63,000 | $0 | 04/14/2008 | F - Formal Settlement | |
| 45. | 03001 | Other | 19100146 G04 | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement | |
| 46. | 03002 | Other | 19101200 E01 I | 03/21/2008 | 12/19/2011 | $0 | $0 | $0 | 04/14/2008 | F - Formal Settlement |
Investigation Summary
On October 2, 2007, Employees #1 through #5 and four coworkers, of RPI Coating, Inc., were staging materials in a penstock. They were using a Graco Xtreme airless sprayer, which heated a two-part epoxy paint. The sprayer was not operating correctly and the crew was directed to use approximately 5 to 10 gallons of methyl ethyl ketone (MEK) to flush the hoses. The flammable MEK vapors and liquids ignited into a flash fire. The resulting heat could have exceeded the decomposition temperature of the Duromar HPL 2510 hardener, and combustion by-products filled the occupied area of the penstock. The crew attempted to escape to a smoke-free area, but the natural ventilation of the penstock caused the smoke and vapors to enter the area into which they fled. Employees #1 through #5 were exposed to carbon monoxide, carbon dioxide and/or to chemical vapors from the decomposition of the Duromar HPL-2510 hardener and base of the epoxy paint. All five employees dies of asphyxia. There were several potential ignition sources, including: 1) the sprayer's heater, which did not appear to be de-energized prior to the use of MEK; 2) static electricity, with the sprayer recycling MEK into the hopper while the sprayer sat on a rolling scaffold; or 3) the electrical wiring, which did not appear to be approved for use in Class I-Division or Class I-Division 2 locations.
Keywords: ASPHYXIATED, MEK, WORK RULES, FIRE, CONSTRUCTION, INHALATION, SPRAY PAINTING, CHEMICAL VAPOR, TOXIC FUMES, CARBON MONOXIDE
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 310470034 | Fatality | Asphyxia | Occupation not reported | ||
| 2 | 310470034 | Fatality | Asphyxia | Occupation not reported | ||
| 3 | 310470034 | Fatality | Asphyxia | Occupation not reported | ||
| 4 | 310470034 | Fatality | Asphyxia | Occupation not reported | ||
| 5 | 310470034 | Fatality | Asphyxia | Occupation not reported |