Sawmill worker killed while unplugging
wood chips from a chipper chute.
A 22-year-old male employee died after being caught by a cable while operating a wood chipper at a sawmill. The family-owned business had been in operation for several years with about 10 employees. Discarded wood pieces from the sawmill were carried on a conveyor belt and fed into the wood chipper. The chipper discharge chute was attached to a section of 12-inch diameter round duct to a hopper, which was 11 feet from the chipper. Wood chips were collected in a container below the hopper, and removed from the area. On the day of the incident, the round duct became plugged. The victim stood on a platform, and with the assistance of another employee, removed the access cover on the hopper, and pushed a straight wire cable (28 feet in length and 5/8 inch in diameter) into the duct, attempting to clean the duct while the chipper was running. The cable was marked with paint, to designate how far it could be inserted safely into the duct. The employee, however, pushed the cable in too far and it was caught by the chipper, which wrapped the cable around his neck, throwing him off the platform. The victim received multiple cervical fractures and died within minutes. During normal hours of operation, the conveyor belt and chipper were in continuous operation and did not have an emergency shutoff.

Following the incident and subsequent OSHA investigation, a safety program was initiated, including specific lockout / tagout procedures to safely turn off the chipper whenever the duct became plugged. Tags were attached to the equipment to identify the machine-specific lockout procedures. An access panel, or clean-out port, was installed in the duct to facilitate easier cleaning. A grate was welded to the top of the main hopper to prevent access.

1. Employers should establish an energy control program in accordance with 29 CFR 1910.147. The program should include procedures and employee training to ensure that equipment is locked out and rendered inoperative, before any employee performs servicing or maintenance on a piece of equipment.

--Employers are required to place a lock on the machine before maintenance, and also when an employee works at the in-feed / discharge area to unclog the chipper.

--Machine access covers should not be opened, nor should the machine be maintained while it is running.

 

2. All maintenance tasks should be carried out only when the machine is locked out. Employers should ensure that machinery operate properly and do not frequently cause hazardous maintenance tasks.

--Clogging was a frequent event, due to the chipper not functioning properly, poor machine design, too many bends in the discharge pipe, restricted airflow, or other problems.

--A clean out system had been devised, but required the machine to be running---a very dangerous procedure!

--Machinery should be in good working order, and not require hazardous maintenance.

 

3. Employers should ensure that a job safety analysis has been performed on all work-related tasks.

--A task can be broken down to a sequence of steps, which are used to identify hazards connected to the task.

--A job safety analysis may have identified the hazard of removing the access door and inserting the cable.

 

4. Employers should develop, implement, and enforce a written safety program.

--A comprehensive safety program should include task-specific safety procedures and employee training.

--Training in the avoidance and abatement of these hazards should be included.

--Employees should have the knowledge, training, and experience to perform their job safely.