FOREST PRODUCTS MANUFACTURING. Focus Report on Preventing Injuries to Workers

Transcription

1 FOREST PRODUCTS MANUFACTURING Focus Report on Preventing Injuries to Workers

2 About the WCB Preventing on-the-job injury and disease is the first priority of the Workers Compensation Board (WCB) of British Columbia. WCB officers inspect worksites in B.C. to make sure they comply with the Occupational Health and Safety Regulation, which sets out minimum workplace standards for health and safety. The WCB also investigates serious workplace accidents and consults with employers, supervisors, and workers to promote health and safety in the workplace. Under the requirements of the Workers Compensation Act, a worker must report an injury or a disabling occupational disease as soon as possible to the employer. The employer must report work-related injuries, occupational diseases, and work-related deaths to the WCB within three days. A worker may not make an agreement with the employer to give up WCB benefits. If a worker suffers a work-related injury or illness, the WCB provides fair compensation that may include medical costs, loss of earnings, physical rehabilitation, and pensions. The WCB also works with employers to help injured workers return to work. If a worker is killed on the job, counselling and financial help are made available to the victim s family. For more information on requirements or eligibility for WCB coverage, contact the WCB office nearest you. WCB Prevention Information Line The WCB Prevention Information Line can answer your questions about workplace health and safety, worker and employer responsibilities, and reporting a workplace accident or incident. The Prevention Information Line accepts anonymous calls. Phone in the Lower Mainland, or call SAFE (7233) toll-free in British Columbia. To report after-hours and weekend accidents and emergencies, call

3 FOCUS FOREST PRODUCTS REPORT ON MANUFACTURING PREVENTING INJURIES TO WORKERS

4 WCB Publications To obtain additional copies of this booklet or other WCB publications, contact: Films and Posters Section Workers Compensation Board of B.C. PO Box 5350 Stn Terminal Vancouver BC V6B 5L5 Phone: in the Lower Mainland , local 3068, toll-free in B.C. Fax: [email protected] 1999 Workers Compensation Board of British Columbia. All rights reserved. The Workers Compensation Board of B.C. encourages the copying, reproduction, and distribution of this document to promote health and safety in the workplace, provided that the Workers Compensation Board of B.C. is acknowledged. However, no part of this publication may be copied, reproduced, or distributed for profit or other commercial enterprise, nor may any part be incorporated into any other publication, without written permission of the Workers Compensation Board of B.C. Canadian Cataloguing in Publication Data Main entry under title: Forest products manufacturing : focus report on preventing injuries to workers ISBN Forest products industry Accidents - British Columbia. 2. Industrial accidents - British Columbia - Statistics. 3. Industrial safety - British Columbia. I. Workers Compensation Board of British Columbia. HD C32B C

5 Highlights of this report From 1993 to 1997, the WCB paid more than $325 million for claims in forest products manufacturing. (See page 7.) Type of claims Number Cost Health-care-only 41,932 $11.5 million Time-loss (STD and LTD, including amputations) 23,800 $297.4 million Fatalities 35 $10.9 million This report highlights the need for improved occupational health and safety programs in forest products manufacturing industries. Employers should review the orientation, training, and supervision of workers in their operations (particularly for workers new to a job) to determine if they are effective in preventing injuries. They should also ensure that they are preventing musculoskeletal injuries. Industry, labour, and the WCB are working together to identify potential engineering and other controls (for example, better safeguarding devices and lockout training) to prevent amputations. Improving health and safety programs in these areas as discussed in Parts 8 and 9 of the report will also help prevent fatalities, the most tragic outcomes of accidents in the workplace. The most common accident types in forest products manufacturing in B.C. from 1993 to 1997 were overexertion, struck-by, and caught-in accidents. (See pages 16, 28, 42, 54, and 66.) Overexertion 27% Other 47% Struck by 16% Caught in 10%

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7 CONTENTS 1. Introduction... 1 About this report... 3 Types of WCB statistics available... 3 Work covered under forest products manufacturing classifications Basic information... 5 Employment trends in forest products manufacturing... 7 WCB claims in forest products manufacturing... 7 Injury rates in forest products manufacturing... 8 Types of accidents in forest products manufacturing Pulp and paper industry Injury rate in the pulp and paper industry Cost of claims in the pulp and paper industry Claims in the pulp and paper industry by occupation Types of accidents in the pulp and paper industry Overexertion Falls from elevation Other-bodily-motion accidents Struck-by accidents Caught-in accidents Fatalities in the pulp and paper industry Sawmills Injury rate in sawmills Cost of claims in sawmills Claims in sawmills by occupation Types of accidents in sawmills Overexertion Struck-by accidents Caught-in accidents Falls from elevation Falls on the same level Fatalities in sawmills Plywood and panel board mills Injury rate in plywood and panel board mills Cost of claims in plywood and panel board mills Claims in plywood and panel board mills by occupation Types of accidents in plywood and panel board mills Overexertion Struck-by accidents Caught-in accidents Falls from elevation Falls on the same level Fatalities in plywood and panel board mills Shake and shingle mills Injury rate in shake and shingle mills Cost of claims in shake and shingle mills Claims in shake and shingle mills by occupation v

8 Types of accidents in shake and shingle mills Struck-by accidents Overexertion Struck-against accidents Caught-in accidents Repetitive-motion claims Fatalities in shake and shingle mills Value-added wood products industry Injury rate in the value-added wood products industry Cost of claims in the value-added wood products industry Claims in the value-added wood products industry by occupation Types of accidents in the value-added wood products industry Overexertion Struck-by accidents Caught-in accidents Struck-against accidents Falls from elevation Fatalities in the value-added wood products industry Preventing accidents and injuries Overview Overexertion Falls Lockout Safeguarding Amputations Creating and maintaining a safe workplace Overview Occupational health and safety programs Supervision and training Responsibilities of supervisors Orientation of new workers A positive approach to health and safety Resources WCB resources Forest Products Manufacturing Advisory Group of British Columbia Employers Advisers Workers Advisers WCB Offices vi

9 1. INTRODUCTION 1

10 About this report Forest products manufacturing in British Columbia as defined by the Workers Compensation Board (WCB) of B.C. encompasses a variety of companies and employers, mostly those who manufacture or work with forest products. The diversity of work in forest products manufacturing means that many different occupations are involved, such as mill labourers, plywood and panel board makers, sawmill sawyers, packaging workers, papermakers, carpenters, and millwrights. The nature of the work done by workers in these occupations and the types of equipment and materials they handle present many on-the-job hazards. Injuries and fatalities in forest products manufacturing result from such things as: Being caught in or struck by machinery Falling from a height Heavy lifting or repetitive movements Twisting or reaching Breathing in noxious or toxic chemicals This report provides employers, supervisors, workers, and health and safety personnel with information about accidents in the forest products manufacturing industries and how to prevent them. Part 1, the introduction, provides a general overview of the purpose of the report, information on the sources of the statistics, and information on the WCB industry rate classification system. Part 2 contains basic information about the forest products manufacturing industries as a group. Part 3 offers information about the pulp and paper industry. Part 4 offers information about sawmills. Part 5 offers information about plywood and panel board mills. Part 6 offers information about shake and shingle mills. Part 7 offers information about the valueadded wood products industry. Part 8 discusses how to prevent common accidents in the forest products manufacturing industries. Part 9 describes how to create and maintain a safe workplace. Part 10 tells how to obtain WCB assistance, information, courses, publications, and videos. Types of WCB statistics available Accident statistics at the WCB are based on accepted injury claims from workers. The following terms are used in this report. Injury rate calculation The WCB compiles average injury rates for various industry groups as well as a provincial average for all industries. Injury rates are based on short-term disability claims and estimated person-years of employment. Person-years are estimated by dividing the gross payrolls submitted by employers by the matching Statistics Canada wage-rate data. Injury rate is then calculated by dividing the number of shortterm disability claims by the estimated number of person-years and multiplying that by 100. This results in a rate expressing the number of claims per 100 person-years of covered employment (100 person-years is the equivalent of 100 full-time employees). Injury rate = Number of STD claims accepted estimated person-years x 100 Health-care-only claims Health-care-only (HCO) claims are claims for which the WCB paid medical expenses but did not replace lost income. These claims are paid through B.C. medical insurance; very little information about these claims is available. Unless otherwise specified, in this report the statistics for claims costs do not include HCO costs. Introduction 3

11 Time-loss claims Time-loss claims include claims where time at work is lost due to a workplace injury that results in a short-term disability (STD), a long-term disability (LTD), or a fatality. STD claims are those where a payment is made for lost income and the worker is expected to return to work. STD claims involve injuries such as broken arms or legs and back strains or sprains. STD claims are used to determine injury rates. LTD claims are those where a pension is awarded for a permanent disability, such as the loss of a limb or finger. Fatality claims are those where a survivor benefit is paid. Period covered in this report Parts 2 to 7 of this report cover the statistics for forest products manufacturing industries for the five-year period from 1993 to 1997, the most recent year for which data were available. Because statistical breakdowns by occupation were unavailable for 1997, the proportions for claims by occupation within each industry sector (expressed as percentages) were derived from data for instead of In forest products manufacturing, the relative rates of claims by occupation do not vary significantly over time. Note: In some tables, charts, and graphs, the percentages do not total 100 due to rounding. Industries covered in this report The industries covered in this report are based on the classification system used for determining WCB assessments for employers. The forest products manufacturing classifications, , , , and , along with the value-added grouping of eight classbins, cover a diverse group of employers. They mostly include companies that manufacture or work with forest products for example, companies that make primary wood supplies (such as pulp, plywood, panel board, shingles) and companies that make secondary wood products (such as doors, pallets, pails, barrels). A detailed list of the work covered under this subclass is shown in the box below. Work covered under forest products manufacturing classifications Pulp and paper mills Sawmills, manufacturing of wood chips (chipping) Manufacturing of flakeboard, hardboard, plywood, and veneer (panel board) Shingle or shake mills Value-added wood products includes the following eight classbins:* Planing mills Manufacturing of fence posts or wooden poles, and log peeling when conducted as a separate industry Lumber remanufacturing, where not part of a sawmill operation Kiln drying Manufacturing of sashes and doors, or moulding Manufacturing of laminated beams Wooden box works, or manufacturing of wooden pallets Manufacturing of excelsior (wood wool), staves or heads, or wooden pails, tubs, pipe, or barrels made of staves * Claims in these eight classbins were combined to provide the information in Part 7. Forest products manufacturing: Focus report 4

12 2. BASIC INFORMATION 5

13 Employment trends in forest products manufacturing In 1997, the equivalent of about 49,000 fulltime workers were employed in the forest products manufacturing industries. This means that about 2.7 percent of the 1.8 million workers in B.C. in 1997 worked in forest products manufacturing. As shown in the graph on the right, employment in this group of industries declined from 1993 to 1997, particularly between 1993 and Number of full-time equivalent workers Employment trends in forest products manufacturing, ,000 50,000 40,000 30,000 20,000 10,000 WCB claims in forest products manufacturing The table below summarizes information about accepted claims in the forest products manufacturing industries from 1993 to It shows that the cost of health-care-only claims is much lower than the cost of timeloss claims, though there are almost twice the number of health-care-only claims. Time-loss claims resulted in 932,856 days lost from work during this five-year period These claims costs do not include other costs of workplace accidents and disease that employers must pay, such as the costs of hiring replacement workers, overtime, and retraining. The pain, suffering, and disability experienced by injured workers are of even greater importance than the financial costs Accepted claims in forest products manufacturing, Number Total Type of claim of claims claims cost Health-care-only claims 41,932 $11.5 million Time-loss claims: 23,800 $297.4 million* STD and LTD, including amputations Time-loss claims: 206 $13.0 million* amputations only Fatality claims 37 $10.9 million *This includes all costs associated with short-term and long-term benefits for time-loss and permanent disability awards. It does not include costs for rehabilitation and health-care benefits. Basic information 7

14 The graph on the right shows the trend of both health-care-only and time-loss claims for the forest products manufacturing industries from 1993 to Claims trend for forest products manufacturing, Number of time-loss claims Number of health-care-only claims 10, Number of claims Injury rates in forest products manufacturing From 1993 to 1997, the average five-year injury rates in the various forest products manufacturing industries ranged from 3.4 (pulp and paper) to 33.2 (shake and shingle mills). During the same period, the average rate in all workplaces in B.C. was 5.4. These figures highlight the hazardous nature of work in forest products manufacturing and the need for safety programs and initiatives. The graph on the right compares the injury rates in forest products manufacturing with the provincial average in all industries for 1993 to More detailed discussion of injury rates is provided in the part for each industry involved in forest products manufacturing (Parts 3 through 7). Injury rate Average injury rates in forest products manufacturing industries and all B.C. industries, Pulp and paper industry Sawmills Plywood and panel board mills Shake and shingle mills Value-added wood products industry All B.C. industries Forest products manufacturing: Focus report 8

15 Types of accidents in forest products manufacturing This report often reviews claims by the types of accidents that caused them. Accidents here include not only sources of claims that happen at a definite point in time (e.g., when a worker is struck by a piece of equipment) but also those involving a longer period (e.g., when a worker develops a repetitive motion injury from continually performing the same task or becomes deaf after exposure to hazardous noise levels for many years). From 1993 to 1997, claims in the forest products manufacturing industries were most often: Overexertion claims, caused by lifting, pushing, pulling, and/or carrying objects Repetitive motion claims, caused by repeated motions where no individual motion was likely to have caused injury Other-bodily-motion claims, caused by reaching, twisting, running, walking, slipping, or tripping without falling Fall-from-elevation claims, due to falls from any height Fall-on-same-level claims, due to tripping on rough or uneven surfaces Struck-by claims, from being struck by moving objects such as equipment, machine parts that break or fly off, or materials handled (e.g., logs, lumber) Struck-against claims, from striking against objects such as equipment or machinery Caught-in claims, from being caught in machinery, equipment, or materials handled Toxic, noxious claims, caused by touching, inhaling, or ingesting toxic or noxious substances Noise exposure claims, caused by a single or repeated exposure to noise Matter-in-eye claims, due to foreign material entering the eye and causing superficial damage (if more serious damage results, the claims are classified as struck-by claims) Motor vehicle accident (MVA) claims, from accidents to or movement of highway or non-highway vehicles Amputations Amputations which often result from caught-in and struck-by accidents, for example are a particular concern in the forest products manufacturing industries. The Prevention Division of the Workers Compensation Board and the forest products manufacturing industries are investigating the potential of engineering and other controls to prevent amputations. From 1993 to 1997, the WCB accepted 206 amputation claims in the forest products manufacturing industries, at a total cost of more than $13 million. The table below shows the number and cost of claims for each of these five years. More detailed information on the causes of and strategies to prevent amputations in forest products manufacturing can be found on pages of this report, in the sections on lockout, safeguarding, and amputations. Amputation claims in forest products manufacturing industries, Year No. of claims Cost of claims $ 3,135, $ 3,056, $ 1,948, $ 1,764, $ 3,127,212 Total 5 yrs. 206 $ 13,032,314 Basic information 9

16 3. PULP AND PAPER INDUSTRY 11

17 Injury rate in the pulp and paper industry From 1993 to 1997, the average injury rate in the pulp and paper industry was 3.4. For the same period, the provincial average in all workplaces in B.C. was 5.4. Injury rates in the pulp and paper industry and all B.C. industries, All B.C. industries Pulp and paper industry The graph on the right compares the injury rate in the pulp and paper industry with the provincial average in all industries for each year from 1993 to The injury rate in the pulp and paper industry dropped from 4 in 1993 and 1994 to 3 in 1995, 1996, and This is a 25 percent decrease. Injury rate Injury rates are also available for individual companies for a given year. The table below shows how the injury rate in the pulp and paper industry in 1997 varied with the size of the company Injury rate in the pulp and paper industry by company size, 1997 Company size Percentage Number Percentage by number of Injury Number of of all of of all workers rate companies companies workers* workers < 50 < % 148 1% 51 to % 146 1% % 16,560 98% All companies % 16, % *full-time equivalent Pulp and paper industry 13

18 Cost of claims in the pulp and paper industry From 1993 to 1997, the total cost of time-loss claims (STD, LTD, and fatalities) in the pulp and paper industry was about $56.4 million. The amount for each of the five years is shown in the graph above right. In 1997, the cost of these claims was about $14.5 million. This was about 2.0 percent of the $740 million total claims costs for all of B.C. Claims costs increased in 1997, due partly to a court decision that reinstated widows benefits. The cost of time-loss claims from 1993 to 1997 can also be broken down by accident type, as shown in the graph below right. Claims costs in millions of dollars Cost of time-loss claims in the pulp and paper industry by year, Cost of time-loss claims in the pulp and paper industry by accident type, Claims costs in millions of dollars Overexertion Fall from elevation Other bodily motion Struck by Caught in Fall on same level Toxic, noxious exposure Struck against Repetitive motion Other Forest products manufacturing: Focus report 14

19 Claims in the pulp and paper industry by occupation As shown in the graph below, the occupations with accepted accident claims in the pulp and paper industry were: Pulp and paper maker (40 percent) Millwright (11 percent) Plumber, pipefitter (6 percent) Other equipment operator (4 percent) Metal-shaping worker (4 percent) Janitor, cleaner (3 percent) Electrical installation and repair worker (3 percent) Heavy-duty mechanic (2 percent) Carpenter or related worker (2 percent) Other (25 percent) Examples of other occupations are packaging worker, stationary engineer, truck driver, and hoist operator. Although pulp and paper makers had the most accidents that resulted in claims, we cannot conclude that pulp and paper making is the most hazardous occupation. Because we do not know the percentage of workers in the pulp and paper industry who are pulp and paper makers, we cannot determine if pulp and paper makers injury rate is higher or lower than the rates of workers in other occupations. Claims in the pulp and paper industry by occupation Electrical installation and repair worker 3% Janitor, cleaner 3% Metal-shaping worker 4% Heavy-duty mechanic 2% Carpenter or related worker 2% Other equipment operator 4% Plumber, pipefitter 6% Pulp and paper maker 40% Millwright 11% Other 25% Pulp and paper industry 15

20 Types of accidents in the pulp and paper industry From 1993 to 1997, the WCB accepted 3,341 time-loss claims (STD, LTD, and fatalities) in the pulp and paper industry. As can be seen in the graph below, these claims resulted from a broad range of accident types. Most claims were due to the following five types of accidents: Overexertion (28 percent) Fall from elevation (12 percent) Other bodily motion (11 percent) Struck by (9 percent) Caught in (7 percent) These types of accidents are discussed in more detail on the following pages. Claims in the pulp and paper industry by accident type, Struck against 4% Toxic, noxious exposure 5% Fall on same level 6% Repetitive motion 3% Overexertion 28% Caught in 7% Struck by 9% Other bodily motion 11% Other 15% Fall from elevation 12% Forest products manufacturing: Focus report 16

21 Overexertion Overexertion accidents are caused by lifting, pushing, pulling, and carrying objects such as paper and pulp items, reels and rolls, and metal objects. Most of these accidents resulted in strain and sprain injuries. From 1993 to 1997, the WCB accepted 915 overexertion claims in the pulp and paper industry. This represented 28 percent of the total number and 18 percent of the total cost of time-loss claims in this industry. The occupations with the most overexertion claims were: Pulp and paper maker (42 percent) Millwright (12 percent) Plumber, pipefitter (7 percent) Metal-shaping worker (4 percent) Carpenter or related worker (3 percent) Electrical installation and repair worker (3 percent) Overexertion claims in the pulp and paper industry, Overexertion 28% Paper, pulp item 7% Reel, roll 6% Other metal object 6% Other object 81% Pulp and paper industry 17

22 Falls from elevation Many falls from elevation involve workers slipping on steps or stairs, or falling from ladders, ramps, platforms, or stationary vehicles. Walking on and getting off of vehicles and equipment (e.g., climbing down from a load) are common activities that workers often do several times each work day and do not perceive as being high-risk. Nevertheless, these activities result in many accidents and injuries. From 1993 to 1997, the WCB accepted 400 fall-from-elevation claims in the pulp and paper industry. This represented 12 percent of the total number and 17 percent of the total cost of time-loss claims in this industry. The percentage of cost (17) is almost onethird higher than the percentage of incidents (12) because injuries were more severe in falls from elevation than in some other types of accidents. The occupations with the most fall-fromelevation claims were: Pulp and paper maker (41 percent) Other equipment operator (9 percent) Millwright (6 percent) Plumber, pipefitter (6 percent) Electrical installation and repair worker (5 percent) Fall-from-elevation claims in the pulp and paper industry, Falls from elevation 12% Falling on steps, stairs 18% Falling from ladder 15% Falling from stationary vehicle 12% Other 55% Forest products manufacturing: Focus report 18

23 Other-bodily-motion accidents Other-bodily-motion claims result from accidents in which an injury is caused by a free bodily motion such as bending or reaching, or when a person slips but does not fall to the ground. From 1993 to 1997, the WCB accepted 376 other-bodily-motion accident claims in the pulp and paper industry. This represented 11 percent of the total number and 6 percent of the total cost of time-loss claims in this industry. The occupations with the most otherbodily-motion claims were: Pulp and paper maker (40 percent) Millwright (24 percent) Plumber, pipefitter (7 percent) Metal-shaping worker (5 percent) Electrical installation and repair worker (5 percent) Other-bodily-motion claims in the pulp and paper industry, Other bodily motion 11% Slipping on floor (inside) 20% Slipping on ground (outside) 22% Slipping on steps, stairs 18% Other 40% Pulp and paper industry 19

24 Struck-by accidents Struck-by claims result from accidents in which workers are struck by moving objects, such as lumber, wooden items, equipment, and machine parts that break or fly off. From 1993 to 1997, the WCB accepted 307 struck-by claims in the pulp and paper industry. This represented 9 percent of the total number and 8 percent of the total cost of time-loss claims in this industry. The occupations with the most struck-by claims were: Pulp and paper maker (36 percent) Millwright (22 percent) Plumber, pipefitter (8 percent) Electrical installation and repair worker (4 percent) Struck-by claims in the pulp and paper industry, Struck by 9% Metal pipe 8% Other metal object 8% Reel, roll 6% Other 78% Forest products manufacturing: Focus report 20

25 Caught-in accidents Caught-in claims represent accidents in which workers are caught in a machine, a piece of equipment, or materials they are working with. From 1993 to 1997, the WCB accepted 231 caught-in claims in the pulp and paper industry. This represented 7 percent of the total number and 12 percent of the total cost of time-loss claims in this industry. The percentage of cost (12) is almost twice as high as the percentage of incidents (7) because injuries were more severe in caughtin accidents than in some other types of accidents. The occupations with the most caught-in claims were: Pulp and paper maker (50 percent) Millwright (23 percent) Packaging worker (4 percent) Electrical installation and repair worker (3 percent) Caught-in claims in the pulp and paper industry, Caught in 7% Other machinery 28% Conveyor 9% Sawmill machinery 5% Other 58% Examples of caught-in accidents A worker was trying to thread paper ends onto rolls. While his left hand was jogging the control switch, his right hand was holding the paper end in place. He accidentally jogged the paper end rolls and caught his right hand in the nip area. A worker was cleaning spilled chips at the crossover belt when the handle of his shovel was caught in a nip-point between the return belt and the return roller. The handle of the shovel drew the worker s right arm and left hand into the nip-point, causing the dislocation of his right elbow and lacerating his right arm and left hand. Pulp and paper industry 21

26 Fatalities in the pulp and paper industry The table below summarizes the fatality claims the WCB accepted in the pulp and paper industry from 1993 to Although some of these accidents occurred before 1993, the claims were accepted from 1993 to Fatalities in the pulp and paper industry, Date of Accident Age Occupation Summary Injury October 2, Insulator Exposure to asbestos and other Asbestosis industrial chemicals. January 12, Supervisor Worker opened pressure vessel and Burns sustained severe burns to more than 50 percent of his body. April 29, Machinist Exposure to asbestos at the worksite. Mesothelioma August 31, Insulator Exposure to asbestos at the worksite. Asbestosis/lung cancer September 9, Mechanic Exposure to asbestos at the worksite. Mesothelioma October 9, Fireman Worker went through port in a Burns recovery boiler and collapsed. December 8, Superintendent Run over by a front-end loader. Severe crushing injuries of upper legs and abdomen November 15, Mechanic Exposure to asbestos at the work site. Mesothelioma January 21, Utility worker Run over by loader. Severe crushing of the chest area February 23, Spare board Worker was standing near a Amputation of right arm worker conveyor-belt mechanism when his arm got caught and pulled into belt. July 21, Repulper Worker was crushed in pinch-point Crushing of torso resulting operator between 2,200 pounds of pulp and a in a broken clavicle and steel wall. death by asphyxiation October 21, Maintenance Worker was found dead in a confined Asphyxiation as a result worker space. of breathing nitrogenenriched atmosphere October 21, Maintenance Worker was found dead in a Asphyxiation as a result worker confined space. of breathing nitrogenenriched atmosphere Forest products manufacturing: Focus report 22

27 4. SAWMILLS 23

28 Injury rate in sawmills From 1993 to 1997, the average injury rate in sawmills was 7.0. For the same period, the average in all workplaces in B.C. was 5.4. The graph on the right compares the injury rate in sawmills with the provincial average in all industries for each year from 1993 to The injury rate in sawmills dropped from 8 in 1993 and 1994 to 6 in 1996 and This is a 25 percent decrease. Injury rates are also available for individual companies for a given year. The table below shows how the injury rate in sawmills in 1997 varied with the size of the company. Injury rates in sawmills and all B.C. industries, Year All industries Sawmills All B.C. industries Sawmills Injury rate Injury rate in sawmills by company size, 1997 Company size Percentage Number Percentage by number of Injury Number of of all of of all workers rate companies companies workers* workers 1 to % 642 2% 11 to % 299 1% 21 to % 946 3% 51 to % 1,487 5% % 25,576 89% All companies % 28, % *full-time equivalent Sawmills 25

29 Cost of claims in sawmills From 1993 to 1997, the total cost of time-loss claims (STD, LTD, and fatalities) in sawmills was about $164.2 million. The cost for each of the five years is shown in the graph above right. In 1997, the cost of these claims was about $34.1 million. This is about 4.6 percent of the $740 million total claims costs for all of B.C. Claims costs increased in 1997, due partly to a court decision that reinstated widows benefits. Accidents causing claims from 1993 to 1997 can also be broken down into cost by accident type, as shown in the graph below right. Cost of time-loss claims in sawmills by year, Claims costs in millions of dollars Cost of time-loss claims in sawmills by accident type, Claims costs in millions of dollars Overexertion Struck by Caught in Fall from elevation Fall on same level Other bodily motion Struck against Repetitive motion Noise exposure Other Forest products manufacturing: Focus report 26

30 Claims in sawmills by occupation As shown in the graph below, the occupations with accepted accident claims in sawmills were: Mill labourer (45 percent) Sawmill sawyer (8 percent) Millwright (8 percent) Other equipment operator (8 percent) Labourer material handler (7 percent) Janitor, cleaner (4 percent) Other (20 percent) Examples of other occupations include packaging worker, mill foreman, truck driver, and hoist operator. Although mill labourers had the most accidents resulting in claims, we cannot conclude that mill labouring is the most hazardous occupation. Because we do not know the percentage of workers in sawmills who are mill labourers, we cannot determine if mill labourers injury rate is higher or lower than the rates of workers in other occupations. Claims in sawmills by occupation Other equipment operator 8% Labourer material handler 7% Janitor, cleaner 4% Millwright 8% Mill labourer 45% Sawmill sawyer 8% Other 20% Sawmills 27

31 Types of accidents in sawmills From 1993 to 1997, the WCB accepted 11,685 time-loss claims (STD, LTD, and fatalities) in sawmills. As can be seen in the graph below, these claims resulted from a broad range of accident types. Most claims were due to the following five types of accidents: Overexertion (27 percent) Struck by (16 percent) Caught in (11 percent) Fall from elevation (9 percent) Fall on same level (7 percent) These types of accidents are discussed in more detail on the following pages. Claims in sawmills by accident type, Other bodily motion 6% Repetitive motion 5% Struck against 5% Noise exposure 4% Overexertion 27% Fall on same level 7% Fall from elevation 9% Other 11% Struck by 16% Caught in 11% Forest products manufacturing: Focus report 28

32 Overexertion Overexertion accidents are caused by lifting, pushing, pulling, or carrying objects. Most of these accidents resulted in strain and sprain injuries. From 1993 to 1997, the WCB accepted 3,209 overexertion claims in sawmills. This represented 27 percent of the total number and 18 percent of the total cost of time-loss claims in sawmills. The occupations with the most overexertion claims were: Mill labourer (42 percent) Labourer material handler (9 percent) Sawmill sawyer (8 percent) Millwright (6 percent) Other mill worker (6 percent) Overexertion claims in sawmills, Overexertion 27% Lumber 35% Post, pole, beam 10% Other wood item 7% Other object 48% Sawmills 29

33 Struck-by accidents Struck-by claims result from accidents in which workers are struck by moving objects, such as lumber, wooden items, equipment, and machine parts that break or fly off. From 1993 to 1997, the WCB accepted 1,819 struck-by claims in sawmills. This represented 16 percent of the total number and 16 percent of the total cost of time-loss claims in sawmills. The occupations with the most struck-by claims were: Mill labourer (39 percent) Sawmill sawyer (8 percent) Labourer material handler (6 percent) Millwright (6 percent) Other mill worker (5 percent) Struck-by claims in sawmills, Struck by 16% Lumber 32% Other wood item 10% Post, pole, beam 8% Other 50% Forest products manufacturing: Focus report 30

34 Caught-in accidents Caught-in claims result from accidents in which workers are caught in a machine, a piece of equipment, or materials they are working with. From 1993 to 1997, the WCB accepted 1,238 caught-in claims in sawmills. This represented 11 percent of the total number and 17 percent of the total cost of time-loss claims in this industry. The percentage of cost (17) is almost one-third higher than the percentage of incidents (11) because injuries were more severe in caught-in accidents than in some other types of accidents. The occupations with the most caught-in claims were: Mill labourer (48 percent) Sawmill sawyer (10 percent) Millwright (7 percent) Labourer material handler (6 percent) Other mill worker (6 percent) Caught-in claims in sawmills, Caught in 11% Lumber 22% Conveyor 15% Sawmill machinery 8% Other 56% Example of a caught-in accident A worker was caught between a swing gate and a conveyorbelt support structure while he was attempting to cut free a jammed log. The worker suffered head and neck injuries. Sawmills 31

35 Falls from elevation Many falls from elevation involve workers slipping on steps or stairs, or falling from ladders, ramps, platforms, or stationary vehicles. Walking on and getting off of vehicles and equipment (e.g., climbing down from a load) are common activities that workers often do several times each work day and do not perceive as high-risk. Nevertheless, these activities result in many accidents and injuries. From 1993 to 1997, the WCB accepted 1,092 fall-from-elevation claims in sawmills. This represented 9 percent of the total number and 12 percent of the total cost of time-loss claims in this industry. The percentage of cost (12) is one-quarter higher than the percentage of incidents (9) because injuries were more severe in falls from elevation than in some other types of accidents. The occupations with the most fall-fromelevation claims were: Mill labourer (34 percent) Other equipment operator (13 percent) Millwright (11 percent) Sawmill sawyer (5 percent) Fall-from-elevation claims in sawmills, Falls from elevation 9% Falling on steps, stairs 18% Falling from stationary vehicle 12% Falling from ramp, platform 11% Other 58% Forest products manufacturing: Focus report 32

36 Falls on the same level Many falls on the same level occur when workers trip on rough or uneven surfaces. From 1993 to 1997, the WCB accepted 779 fall-on-same-level claims in sawmills. This represented 7 percent of the total number and 5 percent of the total cost of time-loss claims in sawmills. The occupations with the most fall-onsame-level claims were: Mill labourer (41 percent) Millwright (10 percent) Sawmill sawyer (6 percent) Other equipment operator (6 percent) Labourer material handler (5 percent) Fall-on-same-level claims in sawmills, Falls on same level 7% Slipping on ground (outside) 30% Slipping on floor (inside) 21% Slipping on conveyor 6% Other 44% Sawmills 33

37 Fatalities in sawmills The table below summarizes the fatality claims the WCB accepted in sawmills from 1993 to Although some of these accidents occurred before 1993, the claims were accepted from 1993 to Fatalities in sawmills, Date of Accident Age Occupation Summary Injury March 14, Trimmerman Worker caught in planer machine. Accidental overdose of medication July 9, Edger operator Exposure to fumes. Idiopathic pulmonary February 27, Welder Exposure to asbestos at work sites. Asbestosis June 25, Filer Heart attack. December 1, Mill worker Vapour from lumber irritated lungs. Asthma Cause of death: complications of severe bronchial asthma. June 29, Sawmill worker Exposure to western red cedar dust. Asthma January 20, Labourer Worker was crushed between a Crushing injuries to head swing gate and conveyor-belt and neck structure while attempting to cut free a jammed log. February 24, Lumber trader Attacked by a bear while on Severe mauling business trip. December 16, Owner Top tow lifts of kiln-dried lumber Crushing injuries fell on worker. January 1, Engineer Asbestos exposure. Mesothelioma May 26, Chipper Worker became ill with flu-like Hantavirus infection symptoms. June 9, Barker operator Fell 5 metres (16 feet) from Broken spine and ruptured operator s booth. aorta October 20, Edgeman While operating an edger, a Trauma to chest and right worker elevated the pressrolls while side the kickback fingers were raised, allowing a cant to kick back, striking the worker in the chest. January 31, Millwright Worker was adjusting banding Massive crushing injury to straps on bander, causing the press head frame to rise. His head was caught between the fixed bulkhead and the rising member. Forest products manufacturing: Focus report 34

38 Date of Accident Age Occupation Summary Injury May 10, Maintenance Malfunction in chipper, which Two broken collar bones, supervisor resulted in blade being thrown broken jaw, ruptured lungs, through inspection port, striking laceration under the chin, worker. gaping wound at left collar bone, and possible severe bleeding from clavical artery June 9, Tail sawyer Worker was straightening a log on Crushing the infeed deck to the head saw when the log rolled off the skid, crushing him. June 10, Watchman Worker disappeared from worksite. His remains were found in sawmill burner. October 28, Logger* Skidder pushed a log forward, Crushing crushing worker. January 12, Debarker Worker was found crushed Crushing injuries to the between drop gate and log deck. shoulder and chest area April 9, Welder Run over by a reversing front-end Severe crushing, amputated loader. right leg, and extensive blood loss *Loggers do not work in sawmills, but companies sometimes engage in activities other than those they register with the Workers Compensation Board. In this case, a company registered as operating a sawmill was also engaged in logging. Sawmills 35

39 5. PLYWOOD AND PANEL BOARD MILLS 37

40 Injury rate in plywood and panel board mills From 1993 to 1997, the average injury rate in plywood and panel board mills was 5.4. For the same period, the provincial average in all workplaces in B.C. was 5.4. Injury rates in plywood and panel board mills and all B.C. industries, All B.C. industries Plywood and panel board mills The graph on the right compares the injury rate in plywood and panel board mills with the provincial average in all industries for each year from 1993 to The injury rate in plywood and panel board mills dropped from 7 in 1993 to 4 in This is a 43 percent decrease. Injury rates are also available for individual companies for a given year. The table below shows how the injury rate in plywood and panel board mills in 1997 varied with the size of the company. Injury rate Injury rate in plywood and panel board mills by company size, 1997 Company size Percentage Number Percentage by number of Injury Number of of all of of all workers rate companies companies workers* workers 1 to % 39 1% 11 to % 45 1% 21 to % 221 3% 51 to % 314 5% % 5,399 90% All companies % 6, % *full-time equivalent Plywood and panel board mills 39

41 Cost of claims in plywood and panel board mills From 1993 to 1997, the total cost of time-loss claims (STD, LTD, and fatalities) in plywood and panel board mills was about $17.0 million. The amount for each of the five years is shown in the graph above right. In 1997, the cost of these claims was about $3.8 million. This is about 0.5 percent of the $740 million total claims costs for all of B.C. Claims costs increased in 1997, due partly to a court decision that reinstated widows benefits. Accidents causing claims from 1993 to 1997 can also be broken down into cost by accident type, as shown in the graph below right. Cost of time-loss claims in plywood and panel board mills by year, Claims costs in millions of dollars Cost of time-loss claims in plywood and panel board mills by accident type, Claims costs in millions of dollars Overexertion Struck by Caught in Fall from elevation Fall on same level Other bodily motion Repetitive motion Struck against MVA Other Forest products manufacturing: Focus report 40

42 Claims in plywood and panel board mills by occupation As shown in the graph below, the occupations with accepted accident claims in plywood and panel board mills were: Plywood and panel board maker (42 percent) Mill labourer (12 percent) Other mill worker (8 percent) Other equipment operator (6 percent) Millwright (5 percent) Janitor, cleaner (4 percent) Other (23 percent) Examples of other occupations are wood-treating workers, electrical repairmen, truck drivers, hoist operators, and heavyduty mechanics. Although plywood and panel board makers had the most accidents that resulted in claims, we cannot conclude that plywood and panel board making is the most hazardous occupation. Because we do not know the percentage of workers in plywood and panel board mills who are plywood and panel board makers, we cannot determine if plywood and panel board makers injury rate is higher or lower than the rates of workers in other occupations. Claims in plywood and panel board mills by occupation Other equipment operator 6% Janitor, cleaner 4% Millwright 5% Other mill worker 8% Mill labourer 12% Plywood and panel board maker 42% Other 23% Plywood and panel board mills 41

43 Types of accidents in plywood and panel board mills From 1993 to 1997, the WCB accepted 1,601 time-loss claims (STD, LTD, and fatalities) in plywood and panel board mills. As can be seen from the graph below, these claims resulted from a broad range of accident types. Nonetheless, most claims were due to the following five types of accidents: Overexertion (28 percent) Struck by (13 percent) Caught in (9 percent) Fall from elevation (9 percent) Fall on same level (7 percent) These types of accidents are discussed in more detail on the following pages. Note: Although from the rounded percentages in the graph below it appears that both other-bodilymotion claims and repetitive-motion claims were as frequent as fall-on-same-level claims, based on the actual number of claims (not shown) fall-onsame level claims were more common. Claims in plywood and panel board mills by accident type, Struck against 5% Repetitive motion 7% Other bodily motion 7% MVA 2% Overexertion 28% Fall on same level 7% Fall from elevation 9% Caught in 9% Struck by 13% Other 13% Forest products manufacturing: Focus report 42

44 Overexertion Overexertion accidents are caused by lifting, pushing, pulling, and carrying objects. Most of these accidents result in strain and sprain injuries. From 1993 to 1997, the WCB accepted 456 overexertion claims in plywood and panel board mills. This represented 28 percent of the total number and 23 percent of the total cost of time-loss claims in this industry. The occupations with the most overexertion claims were: Plywood and panel board maker (47 percent) Other mill worker (13 percent) Mill labourer (12 percent) Other equipment operator (5 percent) Janitor, cleaner (5 percent) Overexertion claims in plywood and panel board mills, Overexertion 28% Plywood veneer 38% Lumber 9% Other wood item 5% Other item 47% Plywood and panel board mills 43

45 Struck-by accidents Struck-by claims result from accidents in which workers are struck by moving objects, such as lumber, wooden items, equipment, or machine parts that break or fly off. From 1993 to 1997, the WCB accepted 208 struck-by claims in plywood and panel board mills. This represented 13 percent of the total number and 11 percent of the total cost of time-loss claims in plywood and panel board mills. The occupations with the most struck-by claims were: Plywood and panel board maker (51 percent) Other mill worker (8 percent) Mill labourer (8 percent) Millwright (7 percent) Other equipment operator (5 percent) Struck-by claims in plywood and panel board mills, Struck by 13% Plywood veneer 11% Miscellaneous hand tool 10% Forklift 10% Other 69% Forest products manufacturing: Focus report 44

46 Caught-in accidents Caught-in claims result from accidents in which workers are caught in a machine, a piece of equipment, or materials they are working with. From 1993 to 1997, the WCB accepted 150 caught-in claims in plywood and panel board mills. This represented 9 percent of the total number and 18 percent of the total cost of time-loss claims in plywood and panel board mills. The percentage of cost (18) is twice as high as the percentage of incidents (9) because injuries were more severe in caught-in accidents than in some other types of accidents. The occupations with the most caught-in claims were: Plywood maker (43 percent) Other mill worker (12 percent) Mill labourer (11 percent) Janitor, cleaner (7 percent) Caught-in claims in plywood and panel board mills, Caught in 9% Conveyor 22% Belt, shaft, chain 21% Other sawmill machinery 7% Other 49% Examples of caught-in accidents A worker was testing the tightness of a drive pulley when a second worker started up the machinery. The first worker s right ring finger was compressed between the belt and pulley. A worker was performing maintenance on a stacker when he was pinned between an air ram cylinder and an accumulator mechanism. The worker suffered a head injury. Plywood and panel board mills 45

47 Falls from elevation Many falls from elevation occur when workers slip on steps or stairs, or fall from ladders, ramps, platforms, or stationary vehicles. Walking on and getting off of vehicles and equipment (e.g., climbing down from a load) are common activities that workers often do several times each work day and do not perceive as high-risk. Nevertheless, these activities result in many accidents and injuries. From 1993 to 1997, the WCB accepted 147 fall-from-elevation claims in plywood and panel board mills. This represented 9 percent of the total number and 11 percent of the total cost of time-loss claims in plywood and panel board mills. The occupations with the most fall-fromelevation claims were: Plywood and panel board maker (36 percent) Other equipment operator (15 percent) Millwright (10 percent) Mill labourer (6 percent) Fall-from-elevation claims in plywood and panel board mills, Falls from elevation 9% Falling from stationary vehicle 18% Falling from ladder 13% Falling on steps, stairs 12% Falling from ramp, platform 12% Other 44% Forest products manufacturing: Focus report 46

48 Falls on the same level Many falls on the same level occur when workers trip on rough or uneven surfaces. From 1993 to 1997, the WCB accepted 118 fall-on-same-level claims in plywood and panel board mills. This represented 7 percent of the total number and 7 percent of the total cost of time-loss claims in plywood and panel board mills. The occupations with the most fall-onsame-level claims were: Plywood and panel board maker (42 percent) Mill labourer (13 percent) Millwright (11 percent) Fall-on-same-level claims in plywood and panel board mills, Falls on same level Slipping on ground (outside) 33% Slipping on floor (inside) 26% Slipping on logs, limbed and unlimbed 5% Other 35% Plywood and panel board mills 47

49 Fatalities in plywood and panel board mills The table below summarizes the single fatality claim in plywood and panel board mills accepted by the WCB from 1993 to Fatalities in plywood and panel board mills, Date of Accident Age Occupation Summary Injury August 15, Apprentice Crushed between an air ram Head injury compression millwright cylinder and an accumulator fracture of skull mechanism Forest products manufacturing: Focus report 48

50 6. SHAKE AND SHINGLE MILLS 49

51 Injury rate in shake and shingle mills From 1993 to 1997, the average injury rate in shake and shingle mills was For the same period, the provincial average in all workplaces in B.C. was 5.4. The graph on the right compares the injury rate in shake and shingle mills with the provincial average in all industries for each year from 1993 to The injury rate in shake and shingle mills dropped from 42 in 1993 to 26 in 1996 and 29 in This is a 38 percent decrease in 1996, and a 31 percent decrease in 1997, both compared to Although these decreases are clearly significant, the resulting injury rate is still unacceptably high. Injury rates in shake and shingle mills and all B.C. industries, Year All industries Shake and shingle mills All B.C. industries Shake and shingle mills Injury rate Injury rates are also available for individual companies for a given year. The table below shows how the injury rate in sawmills in 1997 varied with the size of the company Injury rate in shake and shingle mills by company size, 1997 Company size Percentage Number Percentage by number of Injury Number of of all of of all workers rate companies companies workers* workers 1 to % % 11 to % % 21 to % % 51 to % % % % All companies % % *full-time equivalent Shake and shingle mills 51

52 Cost of claims in shake and shingle mills From 1993 to 1997, the total cost of time-loss claims (STD, LTD, and fatalities) in shake and shingle mills was about $14.9 million. The amount for each of the five years is shown in the graph above right. In 1997, the cost of these claims was about $2.0 million. This is about 0.3 percent of the $740 million total claims costs for all of B.C. Accidents causing claims from 1993 to 1997 can also be broken down into cost by accident type, as shown in the graph below right. Claims costs in millions of dollars Cost of time-loss claims in shake and shingle mills by year, Cost of time-loss claims in shake and shingle mills by accident type, Claims costs in millions of dollars Struck by Overexertion Struck against Caught in Repetitive motion Other Fall from elevation Fall on same level Other bodily motion Matter in eye Forest products manufacturing: Focus report 52

53 Claims in shake and shingle mills by occupation As shown in the graph below, occupations with accepted claims in shake and shingle mills were: Sawyer (29 percent) Mill labourer (25 percent) Labourer material handler (17 percent) Packaging worker (16 percent) Other (13 percent) Examples of other occupations are timber-cutting worker, janitor/cleaner, truck driver, and mechanic foreman. Although sawyers had the most accidents that resulted in claims, we cannot conclude that shake and shingle sawing is the most hazardous occupation. Because we do not know the percentage of workers in shake and shingle mills who are sawyers, we cannot determine if sawyers injury rate is higher or lower than the rates of workers in other occupations. Claims in shake and shingle mills by occupation Millwright 2% Log hoister, sorter 2% Other 7% Mill foreman 1% Other machinist 1% Packaging worker 16% Sawyer 29% Labourer material handler 17% Mill labourer 25% Shake and shingle mills 53

54 Types of accidents in shake and shingle mills From 1993 to 1997, the WCB accepted 2,006 time-loss claims (STD, LTD, and fatalities) in shake and shingle mills. As can be seen from the graph below, these claims resulted from a broad range of accident types. Most claims were due to the following five types of accidents: Struck by (25 percent) Overexertion (24 percent) Struck against (14 percent) Caught in (10 percent) Repetitive motion (7 percent) These types of accidents are discussed in more detail on the following pages. Claims in shake and shingle mills by accident type, Other bodily motion 3% Fall on same level 4% Fall from elevation 4% Matter in eye 2% Struck by 25% Other 7% Repetitive motion 7% Caught in 10% Overexertion 24% Struck against 14% Forest products manufacturing: Focus report 54

55 Struck-by accidents Struck-by claims result from accidents in which workers are struck by moving objects, such as lumber, wooden items, equipment, and machine parts that break or fly off. From 1993 to 1997, the WCB accepted 502 struck-by claims in shake and shingle mills. This represented 25 percent of the total number and 19 percent of the total cost of time-loss claims in shake and shingle mills. The occupations with the most struck-by claims were: Sawyer (34 percent) Other mill worker (23 percent) Labourer material handler (18 percent) Packaging worker (9 percent) Mill labourer (6 percent) Struck-by claims in shake and shingle mills, Struck by 25% Block of wood 33% Other wood item 10% Shingles 9% Other 48% Shake and shingle mills 55

56 Overexertion Overexertion accidents are caused by lifting, pushing, pulling, and carrying objects such as blocks of wood, bales or bundles of wood shavings, or other wood items. Most of these accidents result in strain and sprain injuries. From 1993 to 1997, the WCB accepted 482 overexertion claims in shake and shingle mills. This represented 24 percent of the total number and 13 percent of the total cost of time-loss claims in shake and shingle mills. The occupations with the most overexertion claims were: Packaging worker (26 percent) Sawyer (25 percent) Other mill worker (21 percent) Labourer material handler (18 percent) Mill labourer (3 percent) Overexertion claims in shake and shingle mills, Overexertion 24% Block of wood 45% Bundle, bale 22% Other wood item 6% Other 26% Forest products manufacturing: Focus report 56

57 Struck-against accidents Struck-against claims result from accidents in which a worker strikes an object and this causes an injury. From 1993 to 1997, the WCB accepted 279 struck-against claims in shake and shingle mills. This represented 14 percent of the total number and 21 percent of the total cost of time-loss claims in this industry. The percentage of cost (21) is one-third higher than the percentage of incidents (14) because injuries were more severe in struck-against accidents than in some other types of accidents. The occupations with the most struckagainst claims were: Sawyer (62 percent) Other mill worker (18 percent) Labourer material handler (8 percent) Packaging worker (6 percent) Struck-against claims in shake and shingle mills, Struck against 14% Other machine saw 39% Head saw 15% Trimmer 11% Other 35% Shake and shingle mills 57

58 Caught-in accidents Caught-in claims result from accidents in which workers are caught in a machine, a piece of equipment, or materials they are working with. From 1993 to 1997, the WCB accepted 207 caught-in claims in shake and shingle mills. This represented 10 percent of the total number and 12 percent of the total cost of time-loss claims in this industry. The occupations with the most caught-in claims were: Sawyer (36 percent) Other mill worker (28 percent) Labourer material handler (19 percent) Mill labourer (5 percent) Caught-in claims in shake and shingle mills, Caught in 10% Block of wood 31% Other machine saw 14% Conveyor 11% Other 43% Example of a caught-in accident A worker s arm was caught in the feedworks for a shake resaw machine when it started while he was changing saw blades. The worker s hand and arm were badly lacerated. A worker was trimming shingles when his hand was pulled into the trim saw. The worker s thumb and fingers were severed. Forest products manufacturing: Focus report 58

59 Repetitive-motion claims Repetitive motion 7% Repetitive-motion claims result from repeated free bodily motions where no individual repetition was likely to have caused the injury. From 1993 to 1997, the WCB accepted 132 repetitive-motion claims in shake and shingle mills. This represented 7 percent of the total number and 5 percent of the total cost of time-loss claims in this industry. The occupations with the most repetitivemotion claims were: Sawyer (34 percent) Other mill worker (26 percent) Packaging worker (24 percent) Labourer material handler (11 percent) Shake and shingle mills 59

60 Fatalities in shake and shingle mills The table below summarizes the single fatality claim in shake and shingle mills accepted by the WCB from 1993 to Fatalities in shake and shingle mills, Date of Accident Age Occupation Summary Injury July 4, Superintendent Electrocuted while repairing an Electrocution electrical foot control. Forest products manufacturing: Focus report 60

61 7. VALUE-ADDED WOOD PRODUCTS INDUSTRY 61

62 Injury rate in the value-added wood products industry From 1993 to 1997, the average injury rate in the value-added wood products industry was For the same period, the provincial average in all workplaces in B.C. was 5.4. The graph on the right compares the injury rate in the value-added wood products industry with the provincial average in all industries for each year from 1993 to The injury rate in the valueadded wood products industry has remained fairly consistent, between 20 and 22, from 1993 to Injury rates are also available for individual companies for a given year. The table below shows how the injury rate in the value-added wood products industry in 1997 varied with the size of the company. Injury rates in the value-added wood products industry and all B.C. industries, Year All industries Value-added wood products All B.C. industry industries Value-added wood products industry Injury rate Injury rate in the value-added wood products industry by company size, 1997 Company size Percentage Number Percentage by number of Injury Number of of all of of all workers rate companies companies workers* workers % % 11 to % % 21 to % 1,666 38% 51 to % % % 135 3% All companies % 4, % *full-time equivalent Value-added wood products industry 63

63 Cost of claims in the valueadded wood products industry From 1993 to 1997, the total cost of time-loss claims (STD, LTD, and fatalities) in the value-added wood products industry was about $28.1 million. The amount for each of the five years is shown in the graph above right. In 1997, the cost of these claims was about $5.0 million. This is about 0.7 percent of the $740 million total claims costs for all of B.C. Accidents causing claims from 1993 to 1997 can also be broken down into cost by accident type, as shown in the graph below right. Cost of time-loss claims in the value-added wood products industry by year, Claims costs in millions of dollars Cost of claims in the value-added wood products industry by accident type, Claims costs in millions of dollars Overexertion Struck by Caught in Struck against Fall from elevation Repetitive motion Other bodily motion Fall on same level Matter in eye Other Forest products manufacturing: Focus report 64

64 Claims in the value-added wood products industry by occupation As shown in the graph below, occupations with claims in the value-added wood products industry were: Mill labourer (38 percent) Wood products worker (17 percent) Plywood and panel board maker (6 percent) Sawyer (5 percent) Other (34 percent) Although mill labourers had the most accidents that resulted in claims, we cannot conclude that mill labouring is the most hazardous occupation. Because we do not know the percentage of workers in the valueadded wood products industry who are mill labourers, we cannot determine if mill labourers injury rate is higher or lower than the rates of workers in other occupations. Examples of other occupations are heavy-duty mechanic, janitor/cleaner, truck driver, mechanic foreman, and glazier. Claims in the value-added wood products industry by occupation Other mill worker 3% Other equipment operator 4% Packaging worker 3% Labourer material handler 2% Wood machinist 4% Sawyer 5% Plywood and panel board maker 6% Mill labourer 38% Wood products worker 17% Other 18% Value-added wood products industry 65

65 Types of accidents in the valueadded wood products industry From 1993 to 1997, the WCB accepted 4,961 time-loss claims (STD, LTD, and fatalities) in the value-added wood products industry. As can be seen from the graph below, these claims resulted from a broad range of accident types. Most claims were due to the following five types of accidents: Overexertion (27 percent) Struck by (21 percent) Caught in (11 percent) Struck against (9 percent) Fall from elevation (6 percent) These types of accidents are discussed in more detail on the following pages. Claims in the value-added wood products industry by accident type, Fall on same level 4% Other bodily motion 5% Repetitive motion 5% Matter in eye 2% Overexertion 27% Fall from elevation 6% Other 9% Struck against 9% Struck by 21% Caught in 11% Forest products manufacturing: Focus report 66

66 Overexertion Overexertion accidents are caused by lifting, pushing, pulling, and carrying objects such as lumber, posts, and beams. Most of these accidents resulted in strain and sprain injuries. From 1993 to 1997, the WCB accepted 1,363 overexertion claims in the value-added wood products industry. This represented 27 percent of the total number and 18 percent of the total cost of time-loss claims in the value-added wood products industry. The occupations with the most overexertion claims were: Mill labourer (38 percent) Wood product assembly worker (17 percent) Plywood and panel board maker (6 percent) Sawyer (6 percent) Wood machining worker (6 percent) Overexertion claims in the value-added wood products industry, Overexertion 27% Lumber 31% Other wood item 9% Post, pole, beam 7% Other 52% Value-added wood products industry 67

67 Struck-by accidents Struck-by claims result from accidents in which workers are struck by moving objects, such as lumber, wooden items, equipment, or machine parts that break or fly off. From 1993 to 1997, the WCB accepted 1,036 struck-by claims in the value-added wood products industry. This represented 21 percent of the total number and 12 percent of the total cost of time-loss claims in this industry. The occupations with the most struck-by claims were: Mill labourer (34 percent) Wood product assembly worker (22 percent) Wood machining worker (7 percent) Sawyer (7 percent) Plywood and panel board maker (6 percent) Struck-by claims in the value-added wood products industry, Struck by 21% Lumber 24% Power nailer, power stapler 8% Post, pole, beam 8% Other 60% Forest products manufacturing: Focus report 68

68 Caught-in accidents Caught-in claims result from accidents in which workers are caught in a machine, a piece of equipment, or materials they are working with. From 1993 to 1997, the WCB accepted 555 caught-in claims in the value-added wood products industry. This represented 11 percent of the total number and 21 percent of the total cost of time-loss claims in this industry. The percentage of cost (21) is nearly double the percentage of incidents (11) because injuries are more severe in caughtin accidents than in some other types of accidents. The occupations with the most caught-in claims were: Mill labourer (53 percent) Wood product assembly worker (13 percent) Sawyer (6 percent) Packaging worker (4 percent) Caught-in claims in the value-added wood products industry, Caught in 11% Lumber 28% Other machinery 12% Conveyor 11% Other 48% Examples of caught-in accidents A worker was activating a jump saw when his hand was caught in the cutting area. The worker s right hand between the wrist and knuckles had to be amputated. A worker was changing the knives in a fence-post pointer when a second worker activated the machine. The first worker was caught in the machine and suffered massive head injuries, a separated collarbone, and bruising to the shoulder. Value-added wood products industry 69

69 Struck-against accidents Struck-against claims result from accidents in which a worker strikes an object and this causes an injury. From 1993 to 1997, the WCB accepted 434 struck-against claims in the value-added wood products industry. This represented 9 percent of the total number and 14 percent of the total cost of time-loss claims in this industry. The percentage of cost (14) is onethird higher than the percentage of incidents (9) because injuries were more severe in struck-against accidents than in some other types of accidents. The occupations with the most struckagainst claims were: Mill labourer (34 percent) Wood product assembly worker (22 percent) Sawyer (7 percent) Wood machining worker (7 percent) Plywood and panel board maker (6 percent) Struck-against claims in the value-added wood products industry, Struck against 9% Other machine saw 34% Planer, press 8% Lumber 7% Other 51% Forest products manufacturing: Focus report 70

70 Falls from elevation Many falls from elevation occur when workers slip on steps or stairs, or fall from ladders, ramps, platforms, or stationary vehicles. Walking on and getting off of vehicles and equipment (e.g., climbing down from a load) are common activities that workers often do several times each work day and do not perceive as high-risk. Nevertheless, these activities result in many accidents and injuries. From 1993 to 1997, the WCB accepted 313 fall-from-elevation claims in the valueadded wood products industry. This represented 6 percent of the total number and 11 percent of the total cost of time-loss claims in this industry. The percentage of cost (11) is nearly double the percentage of incidents (6) because injuries were more severe in falls from elevation than in some other types of accidents. The occupations with the most fall-fromelevation-claims were: Mill labourer (40 percent) Other equipment operator (13 percent) Wood product assembly worker (11 percent) Plywood and panel board maker (6 percent) Fall-from-elevation claims in the value-added wood products industry, Falls from elevation 6% Falling from ramp, platform 16% Jumping from stationary vehicle 13% Falling from stationary vehicle 12% Other 58% Value-added wood products industry 71

71 Fatalities in the value-added wood products industry The table below summarizes the fatality claims in the value-added wood products industry accepted by the WCB from 1993 to Although one of these accidents occurred before 1993, the claim was accepted between 1993 and Fatalities in the value-added wood products industry, Date of Accident Age Occupation Summary Injury October 15, Supervisor Worker apparently looked inside small door of burner when a pile of shavings fell on him. April 14, Lumber stripper Worker was struck by a forklift, which backed up and ran over him. Suffocation Crushing of lower body Forest products manufacturing: Focus report 72

72 8. PREVENTING ACCIDENTS AND INJURIES 73

73 Overview This section provides safety information for preventing accidents that commonly occur in forest products manufacturing industries. This section discusses these safety topics: Overexertion Falls Lockout Safeguarding Amputations Each of these topics is discussed in detail in the following pages, as are one of the most preventable forms of injuries, amputations. Preventing accidents and injuries 75

74 Overexertion The main causes of overexertion accidents are activities that involve lifting, pushing, pulling, and carrying; incorrect handling of objects; and improper use of tools. For example, overexertion can be caused by manually lifting heavy loads or pushing and pulling loaded carts; using a peevee to move a large log or cant, or to reposition a chain onto a sprocket drive; using pike poles while in a poor position. Other factors that lead to overexertion accidents include: Bending over, stretching, or twisting to reach loads for example, feeding veneer on a lay-up line, pulling veneer at the green end, off-bearing lumber or veneer from the green chain Handling loads that are difficult to grasp for example, shake blocks, wood products, 6 x 6 boards, bags without handles Working in an uncomfortable or awkward posture for a prolonged period of time for example, working in engine compartments (mechanics), changing guides and saws (sawfilers) Carrying loads over long distances or for long periods of time for example, piling bundles of shingles or shakes; lugging pails (oilers); hauling bucked logs to the waste conveyor (clean-up workers) Applying a force repeatedly for example, placing strips between layers of lumber Working with the wrist, elbow, or shoulder in an extreme position for example, working on poorly designed consoles, flipping 2 x 10 boards on a high deck (graders) Most injuries cannot be attributed to just one particular risk factor; however, overexertion is the main contributing factor in nearly all of these examples. Employers can help prevent many overexertion accidents by: 1. Identifying the risk factors tasks within a job that may contribute to overexertion accidents 2. Assessing the risk to workers 3. Consulting workers to find ways to lessen the risk factors 4. Designing and implementing solutions and safe work procedures 5. Training workers in safe work procedures and in proper use of tools and equipment For more information A guide to developing an effective ergonomic program in the workplace is provided in Controlling musculoskeletal injury (MSI) risk factors on page 92 of this report. For more information on preventing overexertion accidents, see the Occupational Health and Safety Regulation, Part 4, and the WCB publication Back Talk: An Owner s Manual for Backs. Forest products manufacturing: Focus report 76

75 Ways to prevent overexertion accidents In general, employers and supervisors can help to prevent overexertion accidents by: Scheduling short, regular breaks Alternating work that has a high risk of causing overexertion with work that does not Providing regular training in good body mechanics Some other ways to prevent overexertion accidents are specific to the type of work involved, such as manual lifting, tool use, or pushing and pulling. Ways to prevent overexertion accidents from manual lifting Employers/Supervisors: Provide conveyors, wheelbarrows, ball-caster tables, roller chains, dollies, cranes, forklifts, come-alongs, hand trucks, and/or carts where needed. Train workers in proper lifting techniques and when to use them (for example, differentiate among a golfer s lift, a tripod lift, and a power lift). Purchase smaller packaged loads to ensure that packages are lighter as well as less bulky. Workers: Use mechanical devices or get other workers to help when handling large, heavy, or awkward objects. Use proper lifting techniques. Maintain a neutral spine when lifting. Keep objects as close to your body as possible when lifting. Keep the height of objects requiring manual handling between knuckle and chest height. Never place extremely heavy objects that must be manually handled down at floor level or above chest level. Alternate the use of the left and right sides of the body. Ways to prevent overexertion accidents when using tools Employers/Supervisors: Purchase tools that keep the hand and forearm in a straight position. Support or suspend tools (for example, use overhead suspensions with counterbalances). Purchase tools with anti-vibration sleeves built in or with vibration levels above 1500 Hz. Purchase tools with grips of approximately 1.5" diameter. Maintain tools regularly according to manufacturers recommendations and keep tool parts tight. Workers: Where possible, alternate between tools to give your muscles a change. Stretch your hands and forearms often when muscles are warm. Use the proper tool for the job. Grasp tools as lightly as possible and let the tools do the work. Use pikepoles of an adequate length and position the body in a neutral, steady position. Ways to prevent overexertion accidents from pushing and pulling activities Employers/Supervisors: Make sure that wheels and/or casters on hand trucks, carts, and dollies have proper lubrication, are adequately maintained, and are the correct size. Ensure that powered machines are available to do pushing and pulling if possible (for example, provide a forklift for pulling carts). Workers: Alternate high-risk work with work that is lower-risk or uses different body parts, to give specific body parts a rest. Use good body mechanics. Make sure that wheels and/or casters on hand trucks, carts, and dollies have proper lubrication, are adequately maintained, and are the correct size. Use powered machines to do pushing and pulling if possible (for example, use a forklift to pull a cart). Use pikepoles of an adequate length and position the body in a neutral, steady position.

76 Falls The most common types of falls in forest products manufacturing are: Falls on stairs Falls from ladders Falls when entering or leaving (accessing or egressing) stationary vehicles Falls from ramps or platforms Falls from elevation from stationary vehicles Many of these falls occur at heights less than 3 m (10 ft.), where fall protection is not normally required. Fall Protection Guidelines To address hazards and comply with the fall protection requirements in the Occupational Health and Safety Regulation, each company must conduct an evaluation of its worksite to identify areas where: A fall of 3 m (10 ft.) or more may occur, or A fall from a lesser height but with an unusual risk of injury may occur (for example, roof work, log/lumber transfer decks, conveyors, and during saw/knife changes) After completing the evaluation, each company will develop a site fall protection plan, which must address the following: The permanent methods and systems of fall protection that will be used in areas identified as needing fall protection The interim methods and systems of fall protection that will be used until the permanent methods are installed How the methods and systems of fall protection will be evaluated on an ongoing basis Fall protection plan outline The following outline can be used to develop a fall protection plan. Information specific to a worksite can be included under the following headings: Introduction Principles of fall protection Instruction and training Guardrails Floor and roof openings Personal fall restraint equipment Horizontal lifelines Fall protection policy Site-specific work plans Work procedures Scaffolds Ladders Personal fall arrest equipment Dedicated emergency platforms Elevated work platforms Forest products manufacturing: Focus report 78

77 How to instruct workers in using the fall protection equipment and systems prior to their use Provisions for the inspection and maintenance of fall protection equipment and systems by qualified workers prior to their use and at the intervals specified by the manufacturer or a registered professional engineer Adequate supervision strategies to ensure that workers use fall protection equipment and systems appropriately Procedures for rescuing a worker who has fallen and is unable to perform self-rescue Examples of fall-from-elevation accidents A worker apparently fell out of the operator s booth from a height of 5 meters (16 feet). The worker suffered a broken spine and a ruptured aorta. A worker fell through an unguarded opening in an unscrambler transfer deck at a height of 5 meters (16 feet). The worker suffered a head injury and abdominal bleeding. Preventing accidents and injuries 79

78 Lockout Lockout is the use of a lock or locks to render machinery or other equipment inoperable, or to isolate an energy source, such as electrical, mechanical, chemical, or thermal energy in accordance with a written procedure. The purpose of lockout is to prevent the unexpected energization or start-up of machinery or equipment, or the unexpected release of an energy source, that could cause injury to a worker. Many B.C. workers are injured each year when machinery or equipment is not properly locked out. Caught-in and struckby accidents, for example, are often caused by failure to lock out. If machinery or equipment is shut down for maintenance, no work may be done until all of the following have been completed: All parts and attachments have been secured so they cannot inadvertently be moved Any hazard to workers from energy sources has been effectively controlled Energy-isolating devices such as switches, circuit breakers, and valves have been properly locked out Example of a fatality caused by improper lockout A 51-year-old superintendent in a shake and shingle mill was electrocuted while repairing an electrical foot control that had not been properly de-energized and locked out. Locking out machinery and equipment A written lockout procedure is required in all operations where lockout may need to be performed. Every worker who may be required to lock out equipment or machinery, or to supervise workers who perform lockout, must know the following five basic steps. These steps apply to all types of machinery and equipment. 1. Identify the machinery or equipment that needs to be locked out. 2. Make sure the machinery has stopped. 3. Identify and de-activate the main energy-isolating device for each energy source. 4. Apply personal locks to the energy-isolating device. 5. After ensuring that all workers are in the clear of any potential hazards, test the lockout to make sure it is effective. Forest products manufacturing: Focus report 80

79 All machinery or equipment must be locked out whenever the health or safety of a worker could be endangered if hazardous energy is released. To determine if lockout is needed, take the following steps: 1. View the location where the work is to be done. 2. Identify all energy sources. 3. Consider what the result would be if any of the energy sources was released. Would the release of energy be hazardous to a worker? If there is a hazard to workers, lockout is required. Use a lock on energy-isolating devices to prevent hazardous energy from being released if, for example, a switch was accidentally turned on and a machine started. If there is no hazard to workers, lockout is not required and workers can follow normal safe work procedures. A machine-specific written lockout procedure is required when multiple lockout points are involved, or when the procedure for locking out is otherwise complex, requiring, for example, pinning, blocking, or isolating other sources of energy. The written procedure must clearly identify the individual lockout points and the process for ensuring de-energization. Normal production access to transfer decks and lumber package rollcases Part 27 of the Occupational Health and Safety Regulation allows access to transfer decks and lumber package rollcases for normal production work when hazards are controlled. However, if a risk assessment identifies hazards that pose a threat of injury, then the equipment must be locked out before access is allowed. For more information For more information on lockout, see the Occupational Health and Safety Regulation, Part 10, and the WCB publication Lockout. Preventing accidents and injuries 81

80 Safeguarding Safeguarding refers to the use of a variety of devices, either singly or in combination, to provide effective protection to workers from hazards such as those that result in caught-in accidents. Sources of Injuries Workers are exposed to injury from machines in three general ways: from power transmission hazards, from point-ofoperation hazards, and from materials ejected into the air. 1. Power transmission hazards exist whenever any moving part of a machine transfers power from a power source to a point of operation. This is typically the power train portion of the machine and includes such things as: V belt drives Chain/sprocket drives Gears Couplings Shafts and pulleys 2. Point-of-operation hazards are danger areas in a machine where material is being formed, cut, or otherwise worked on. This is usually the working area of the machine where the operator feeds or removes materials. Some typical points of operation are: Cutting area Table saw Bandsaw Hula saw Chop saw 3. Materials that could be ejected by a machine can be extremely hazardous. These materials include flying or ejected material from edgers, debarkers, planers, and other wood-processing equipment. Some examples include: Chips and knots Teeth and shanks from circular saws Slivers of wood from cutting and planing These three sources of injury power transmission, point of operation, and ejected materials must be safeguarded where a hazard to a worker is known or is likely to occur. Examples of fatalities caused by failure to safeguard machinery A millwright was drawn into the unguarded head spool of a belt conveyor and suffered fatal injuries. A lumber piler was strangled when his loose clothing caught on an exposed keyway at the end of a slow-moving shaft. In these two examples, death resulted from unguarded or inadequately maintained machinery and equipment. Safeguarding procedures are essential for preventing such accidents in the workplace. Forest products manufacturing: Focus report 82

81 Hazards Examples of mechanical hazards associated with machinery and the types of accidents they can cause include: Entanglement, snagging, and in-running nip points (caught-in accidents) Crushing, shearing, and cutting (caught - in accidents) Impact hazards (struck-by accidents) Friction and abrasion hazards (rubbed or abraded accidents) Safely contain any materials or parts that could be ejected from the guarded area Be designed, where practicable, to allow lubrication and standard maintenance without removing the guard 2. A safety device restricts access while hazardous parts of a machine are in motion. When access to danger areas of a machine is required during normal operations, a safety device is often the only reasonable solution. A worker operating and maintaining machinery can suffer injuries other than those arising directly from a machine. These include: Adverse effects from harmful emissions, heat, noise, vibration, or radiation Soft-tissue injuries to hands, arms, or neck due to repetitive motion or overexertion Slips and falls from and around machinery Injuries due to fire, explosion, or electrocution from faulty electrical components The hazards identified above require safeguards. Sometimes a safeguard used to eliminate or lessen one hazard will conflict with another safeguard. When this is the case, the safeguards must be redesigned and/or safe work procedures introduced to ensure that workers are protected from both hazards. In other instances, one safeguard can effectively deal with two hazards; for example, a guard that prevents access to moving parts may also contain or absorb noise. Kinds of Safeguards There are four kinds of machine safeguards. 1. A guard is usually a physical enclosure, barrier, or perimeter fence that prevents a worker from accessing a danger area. A guard should be the first option considered for safeguarding hazards. All machine guards must: Prevent a worker from reaching over, under, around, or through the guard or barrier to the danger area Not create additional hazards from pinch points between the guard and moving machine parts Be designed, fabricated, and installed to meet the regulated reach distances referred to in CSA Standard Z432-94, Safeguarding of Machinery A safety device can perform in one of the following ways: It can prevent the machine from starting or cycling if any part of a worker s body approaches or remains in the danger area by using: - A presence-sensing device such as a light curtain or pressure-sensitive mat - two-hand controls properly positioned -A belly bar or panic bar properly positioned -A hold-to-run operating control; this type of control stops the machine when the control is released by the operator It can limit machine movement or travel to a safe range by having a jog, inch, or setup mode activated by special control buttons It can restrain the worker from reaching the danger area at any time during operation by using a safety belt and lanyard anchored and arranged to prevent access to danger area Preventing accidents and injuries 83

82 A shield is a cover or barrier that restricts, but does not entirely prevent, access to a danger area. Examples include: A shield installed over a lathe chuck to prevent contact with extended jaws The kickout/kickback shields and barriers on edgers, resaws, and other similar woodworking equipment An awareness barrier is usually a chain, rope, or other physical marker located well in advance of a danger area. Warning signs should be used with awareness barriers for clear communication of danger. When selecting a safety device, the employer must ensure that the safety distance and control reliability requirements of the CSA Standard Z are met. 3. Shields, awareness barriers, and/or warning signs (both audible and visible) may be used if it is not practical to use a conventional guard or safety device, and if the risk factor is low. Audible signals and flashing lights are warning signs that are often used to signal the start-up of a piece of machinery. These are usually used with machinery such as automated process lines, lumber strapping and wrapping operations, pulp and paper baling lines, and conveyors that are started from a remote location. 4. When all methods of safeguarding a machine have proved impractical, other effective means, such as safe work procedures, hand feeding, and extraction tools, must be used to protect workers. As well, these methods will enhance worker safety when used together with other safeguarding techniques. Examples of these means include using push sticks, featherboards, and jigs. Examples of fatal accidents 27-year-old spare board worker in the pulp and paper industry was standing near a conveyor-belt mechanism when his right arm got caught and pulled into the belt. The worker s arm was amputated and he died of his injuries. A 24-year-old welder in a sawmill was run over by a reversing front-end loader. The worker s body was severely crushed, his right leg was amputated, and he suffered extensive blood loss. Forest products manufacturing: Focus report 84

83 Amputations The WCB is conducting a study of amputations in the forest products manufacturing industries. From 1993 to 1997, there were 176 amputation claims in the sawmill, shake and shingle, and valueadded wood products sectors. The cost of these amputations from 1993 to 1997 totalled $11,994,933 and 23,607 work days (98 person-years) lost. This averages to $68,153 and 134 days lost per claim. Amputation claims in the forest products manufacturing industries are being reviewed for possible solutions to prevent recurrence. As this study progresses, several trends are becoming evident. These trends can be categorized according to machine type, job experience, and occupation. Machine type The majority of amputations happen with saws (29 percent), planers (11 percent), and conveyors (18 percent). The cost of claims involving these machines was more than $8 million. Accidents involving saws, planers, and conveyors accounted for 75 percent of multiple-finger amputations. These facts make a good financial and moral case for investment in machine safety for saws, planers, and conveyors. The Occupational Health and Safety Regulation specifies many requirements that, if properly employed, could have prevented these accidents. Part 12 of the Regulation includes the following requirements: Machinery and equipment must be fitted with adequate safeguards that: - Protect a worker from contact with hazardous power transmission parts - Ensure that a worker cannot access a hazardous point of operation, and - Safely contain any material ejected by the work process that could be hazardous to a worker A safeguard must not be removed or made inoperable until the equipment it is safeguarding has been locked out by proper de-energization and lockout (see Part 10 of Regulation). A belt conveyor must have accessible nip points of spools and pulleys guarded to prevent a worker contacting them. A template, jig, or pushstick must be used if there is risk of injury to a worker s hands when feeding woodworking machinery. Examples of accidents causing amputations A 19-year-old student working part-time in a lumber mill was removing a stick caught in a conveyor drive train. His left hand was caught in the belt, and when he tried to use his right hand to remove it, it too was caught in the belt. His hands were pinned for 20 minutes until help arrived. The severe crushing injury resulted in his right hand being amputated at the wrist and his left hand being partially amputated. A worker with 10 years of experience was promoted to planer feeder. Soon after, he was trying to remove a piece of wood jammed in the machine when his hand was pulled in and severed at the wrist. A 23-year-old worker lost all the fingers and thumb of his hand while trying to remove a board jammed in a planer. The cutter caught his glove, and pulled his hand into the knives. A man was cleaning sawdust off a conveyor when his foot slipped and he was pulled through steel rollers up to his hip. The machine had to be disassembled to free his leg. The leg was amputated above the knee. A 17-year-old student was working a summer job on the chop line. He placed his hand under the saw guard and inadvertently stepped on the activation pedal, severing three fingers. Preventing accidents and injuries 85

84 Job experience Thirty-three percent of amputations occur during a worker s first year of employment with a company. The overall injury rate is even higher 43 percent during a worker s first six months on a given job. Even though a worker may have years of experience with a company, he or she is still at higher risk of injury when starting a new job in that company. From 1993 to 1997, the cost of claims for amputations that occurred during workers first year on the job was more than $4.4 million. Young workers those aged 15 to 24 experienced 22 percent of these amputations. Occupation From 1993 to 1997, more than half the amputations in forest products manufacturing occurred to millwrights, welders, saw operators, and planer operators. Maintenance workers such as millwrights and welders had a high proportion of amputations (17 percent). These workers must often use safe work procedures in circumstances where safeguards would normally be in place. Failure to de-energize or properly lock out machinery has led to numerous amputations. Saw operators account for 28 percent of amputations. Some saw operators (such as shake and shingle sawyers) are constantly working close to the hazard. Preliminary findings indicate that improved training and supervision, operating practices, and equipment safety design would prevent many similar accidents. The next phase of the study will focus on key areas for improvement. This will involve working with stakeholders, among them labour and industry representatives, equipment manufacturers, and the workers at risk, to determine solutions for preventing amputations. Planer operators and feeders also have a high injury rate. Amputations occur to these workers when they try to remove jams. Example of an accident causing an amputation When a 22-year-old chop saw operator tried to activate his saw, it would not start. After clearing some wood out of the way, he tried to confirm the fault. The machine worked this time, but before the worker could move his hand out of the way, it amputated two of his fingers. Forest products manufacturing: Focus report 86

85 9. CREATING AND MAINTAINING A SAFE WORKPLACE 87

86 Overview The statistics presented in this report highlight the need for effective workplace safety measures in the forest products manufacturing industries. This section provides general information and strategies that employers, supervisors, and workers can use to implement and maintain a safe and healthy workplace. This section discusses: Occupational health and safety programs Supervision and training Orientation of new workers A positive approach to health and safety Occupational health and safety programs An occupational health and safety (OHS) program is one of the keys to a safe and healthy workplace. An OHS program should be written and must describe how the employer will manage health and safety in the workplace. An effective OHS program: Provides general direction to management, supervisors, and workers about their responsibilities and roles in providing a safe and healthy workplace Provides specific direction to those responsible for a portion of the program Communicates health and safety policies and procedures Opens the lines of communication by encouraging workers to express their concerns about health and safety An effective OHS program requires active management participation. Whether your organization is large or small, the following points are key to the success of this program: Sincere and active management leadership A desire for a safe and healthy workplace Effective training and supervision of workers Active participation of and co-operation between management and workers Small operations For small forest products manufacturing operations, the OHS program should include, but not be limited to, the following elements: monthly crew meetings; regular inspection of premises; supplementary instructions (written safe work procedures); investigations of accidents; records and statistics; instruction and training of workers; first aid; and WHMIS. Creating and maintaining a safe workplace 89

87 Elements of an occupational health and safety program 1. Occupational health and safety policy: States the employer s commitment to health and safety and the OHS program objectives Defines the responsibilities and roles of the employer, supervisors, and workers 2. Regular inspections of premises: Determine if the worksite, machinery, equipment, and work practices meet health and safety standards Identify unsafe conditions and acts with the potential to cause injury so that corrective measures can be taken Must be conducted at intervals that will prevent the development of unsafe working conditions 3. Supplementary instructions (written safe work procedures): Identify hazards and clarify what must be done to eliminate or minimize the hazards to comply with WCB requirements Guide and direct workers in the safe performance of their jobs Are used as training standards 4. Management meetings: Must be held regularly to review the OHS program activities and to decide both how to make improvements and how to implement recommendations of the OHS committee (see point 7 below) 5. Investigations of accidents: Determine causes of accidents, near misses, injuries, and diseases so that corrective actions can be taken to prevent them from happening again Identify unsafe conditions, unsafe acts, unsafe work procedures, and solutions to prevent a future occurrence of any of these 6. Records and statistics: Document the OHS program s history and improvements Provide a record of program activities such as orientation, training, inspections, accident investigations, and sampling Help identify trends, unusual conditions, and problem areas 7. Joint management-worker OHS committee: Identifies health and safety problems Allows workers to participate in health and safety Provides a forum for solving health and safety problems Recommends to management ways of improving health and safety activities 8. Instruction of workers: Includes training (for example, orientation, crew talks, on-the-job training, and refresher training) to make workers proficient in the safe performance of their jobs Includes on-site direction and instruction by supervisors to ensure that workers perform their jobs safely The elements of an OHS program outlined above are identified in Part 3 of the Occupational Health and Safety Regulation. The Regulation also specifies: The first aid equipment, supplies, facilities, and services required to provide workers with prompt first aid treatment WHMIS requirements, such as labelling and worker training for hazardous substances Possible additional elements in an OHS program include: Emergency preparedness Fall protection Respirator program Claims and disability management For more information For more information on occupational health and safety programs, see the WCB publications How to Implement an Effective Occupational Safety and Health Program and Effective Health and Safety Programs. Forest products manufacturing: Focus report 90

88 Program finds MSI solutions The Industrial Musculoskeletal Injury Prevention Program (IMIRP) is a program of ergonomic evaluations currently underway in B.C. sawmills. IMIRP s goal is to find ways to prevent MSIs (musculoskeletal injuries) in B.C. sawmills. IMIRP is administered by a non-profit society with representatives from the Industrial Wood and Allied Workers of Canada (IWA), the Council of Forest Industries (COFI), and the WCB. The project is funded through WCB assessments. Ergonomists working on the project are analyzing and producing tool kits on common jobs in -sawmills, and in finger-jointing and value-added operations. During the summer of 1999, tool kits covering the majority of sawmill workers in B.C. at risk of MSIs will be available to forest products operations. To order IMIRP tool kits, contact the Films and Posters Section of the WCB (see page 99 of this report). Summary of MSI Prevention Process Establish the core ergonomics team Identify target job Select task team Identify risk factors target These steps are repeated for each job Assess risk factors Develop and implement control measures Follow up control measures Creating and maintaining a safe workplace 91

89 Controlling musculoskeletal injury (MSI) risk factors The Occupational Health and Safety Regulation states that employers are responsible for identifying factors in the workplace that may expose workers to the risk of musculoskeletal injury (MSI), and for eliminating or minimizing the risk. An ergonomic core team of three or four trained people should be established to address the following four topics. 1. Identification of risk factors (a) Identify target jobs: Examine the first aid book Track claims statistics Review accident investigations Solicit worker comments/concerns (b) Select a target job and choose a task team consisting of: Supervisors and workers involved directly with the target job (c) Identify risk factors in the target job by: Drawing a process flow diagram Developing a description of the target job Designing and issuing a questionnaire to identify specific facts about how workers perform the job Observing workers performing the target job 2. Assessment of risk factors Assess the risk of MSI in the target job by determining: How long the risk factor(s) is present in the performing of the job How often the risk factor(s) occurs The severity of the risk factor(s) 3. Control of risk factors Develop and implement a hierarchy of control measures for the target job by: Eliminating risk factors Substituting less hazardous products or procedures - Instituting engineering controls - Introducing administrative controls - Using personal protective equipment 4. Follow-up of control measures to ensure effectiveness Forest products manufacturing: Focus report 92

90 Safe work procedures Workers in forest products manufacturing industries are involved in a wide range of work processes and work with many different types of machinery. Formalized education and training, such as a trade certification, do not replace the need for sitespecific training in safe work procedures and recognizing hazards unique to that particular worksite. For these reasons, it is important that appropriate safe work procedures are available to instruct workers on how to work safely in different situations. Written procedures may be necessary on the basis of regulatory requirements, the nature of hazards, frequency, and/or complexity of the task. Safe work procedures should be developed to address hazards identified through: Regular workplace inspections Accident investigations First aid record reviews Specific concerns raised by workers Safe work procedures are used in the forests products manufacturing industries for the following hazards or situations: Lockout for repair and maintenance work Confined space entry or work Working alone Working in high-traffic areas Control of normal production flow Handling of chemicals and dealing with chemical spills Log bundle breaking Exposure control plans Exposure control plans Exposure control plans are usually implemented when the results of exposure monitoring show that a worker is or may be exposed to an air contaminant at levels greater than 50 percent of its exposure limit. A plan may also be implemented if exposure cannot be measured or determined to be at 50 percent, but a knowledgeable person would conclude that there is a probability that the exposure might exceed 50 percent. The elements of an exposure control plan are listed in section 5.54(2) of the Occupational Health and Safety Regulation. Exposure control plans will be in writing unless a WCB officer determines otherwise. Example of fatalities caused by unsafe work procedures A 32-year-old sawmill worker died from complications of severe bronchial asthma caused by exposure to toxic vapours from lumber. A 46-year-old maintenance worker in the pulp and paper industry was found dead in a confined space. He had been asphyxiated as a result of breathing nitrogen-enriched air. Creating and maintaining a safe workplace 93

91 Investigating accidents and incidents Workers must report accidents and near misses (close calls) to their supervisors. (Near misses are incidents in which no visible injury or damage was done, but that could have caused serious injury or property damage under slightly different circumstances.) Employers are responsible for making sure that all accidents and incidents are investigated promptly. A supervisor and a worker knowledgeable in the work activity usually carry out these investigations. After the investigation is completed, the employer must ensure that an investigation report is prepared and sent to the OHS committee and, if necessary, to the nearest WCB office. An accident investigation should: Determine the cause or causes of the accident Identify any unsafe conditions, acts, or procedures that contributed to the accident Develop recommendations to prevent similar accidents Conducting site inspections A workplace should be monitored in the following five ways. 1. Planned inspections cover the entire operation. These should be carried out on a regular basis and by a cross-section of workers and supervisors or by members of the joint management-worker OHS committee. These inspections include observing both work practices and work conditions. 2. Equipment inspections are carried out regularly by workers who should be trained to inspect their equipment and workplace for potential problems and to be constantly alert for hazards. 3. Special inspections include those done after equipment malfunctions and after accidents occur. 4. Supervisory inspections are ongoing and include job observations and hazard control. 5. Ongoing monitoring of the workplace is carried out by workers looking for potential hazards. Factors that should be considered during the investigation include: Unsafe equipment Unsafe environment Unsafe work practices Unusual or unfamiliar work conditions Poor housekeeping Physical hazards Poor planning Poor instruction/supervision Forest products manufacturing: Focus report 94

92 Supervision and training An effective system of supervision and training is key to preventing workplace injuries particularly injuries to young workers and to workers new to a job. The table on the following page shows the proportion of claims the WCB accepted from young workers compared to claims from workers of all ages. These statistics reinforce the need for adequate training and supervision of workers. Companies with lower accident rates have supervisors that are: Involved with workers and other managers in the development of occupational safety programs and procedures Involved with workers in safety inspections of the workplace and in accident investigations Responsible about providing new employees with safety training In frequent communication with employees about various work issues, including safety Acting as good role models Providing follow-up supervision to ensure that workers understand all of the hazards and work safely Responsibilities of supervisors Supervisors are responsible for exercising due diligence that is, for taking reasonable care to protect workers under their direction and control. Specific responsibilities include: Ensuring that workers are instructed in, trained about, and aware of all hazards at the worksite Assessing workers understanding of safety procedures Following up to ensure that safe work procedures are used Providing specific job instructions and checking thereafter to ensure that those instructions are followed Conducting formal safety inspections Conducting crew talks on a regular basis to alert workers to safety issues Conducting informal daily inspections to ensure that safe work procedures are followed Ensuring that workers have access to and use required personal protective equipment Conducting accident investigations Creating and maintaining a safe workplace 95

93 Orientation of new workers New worker orientation is vital to a healthy and safe work environment. The table below is based on a 50 percent sample of accepted claims in forest products manufacturing from 1995 to It shows the percentage of claims by age group and time on the job. Whether a new worker is new to the work force in forest products manufacturing or new to a particular job within the industries, worker orientation is an essential part of training. A good orientation program will: Help workers understand the consequences of unsafe actions by training them to be aware of hazards and to ask questions when they do not understand what has to be done Provide safety instruction in such areas as confined space entry, pedestrian safety, WHMIS, fall zones, and lockout Include competency-based training on machines such as trim saws, log loaders, boom boats, and forklifts A positive approach to health and safety A positive approach by all workers, including managers, contributes to the development and maintenance of an effective occupational health and safety program and, thereby, to a healthy and safe work environment. It is particularly important that top management have a positive attitude to safety. Management can show its commitment to health and safety by: Preparing a written policy explaining management s attitude towards safety Assigning a health and safety coordinator with the authority to address problems Reviewing group and departmental safety performance on a regular basis Using good safety performance as a measure of good management Research indicates the following points: Companies with lower worker turnover rates have lower injury rates. Management reports better industrial relations at companies with low injury rates than at companies with higher injury rates. The more workers are provided with opportunities to participate in the decision-making process, the lower the injury rate. Periodic and comprehensive safety inspections lead to lower rates of timeloss injuries. Estimated percentage of claims in forest products manufacturing by age group and time on the job, Time on the job Ages Ages All ages Less than 2 months 30% 13% 9% 2 6 months 43% 35% 19% 7 12 months 13% 18% 12% More than 12 months 14% 34% 60% Forest products manufacturing: Focus report 96

94 10. RESOURCES 97

95 WCB resources Prevention Information Line The WCB Prevention Information Line answers questions on: Health and safety requirements Employer and worker responsibilities under the Workers Compensation Act General safety and hygiene topics First aid requirements Reporting an accident or incident You can also call to report workplace health and safety concerns. Anonymous calls are accepted. During business hours, call or call toll-free SAFE (7233). For after-hours and weekend emergencies, call Electronic reporting of accidents and injuries Employers have a number of options for reporting accident and injury information to the WCB electronically. Each option provides employers with an alternative to completing the paper version of Form 7 (Employer s Report of an Accident), Form 7A (First Aid Report), and the Accident Investigation Report. Electronic reporting offers employers a number of advantages, including improved statistical reporting and better communication with the WCB. Electronic reporting options include: EmployerConnect (the WCB s Internetbased reporting system), third-party software products, specifications for developing systems in-house, third-party service providers, and AIRS (Accident and Injury Reporting System). For more information about these options, contact the electronic reporting help desk by phone at or , or by at hyperlink mailto:[email protected] [email protected]. WorkSafe Education Network To increase the accessibility of health and safety education and training, the WCB has formed partnerships with B.C. educational institutions to provide community-based education courses. Most college campuses in B.C., the British Columbia Institute of Technology, the University of Northern B.C., and various school districts offer WorkSafe education courses. The courses available at time of publication are: Occupational Health and Safety in Small Business Hazard Recognition and Control Investigating and Controlling Sprains and Strains Occupational Health and Safety Committee Training Supervisor Safety Management Preventing Workplace Violence Other courses are being developed. For more information, or to register for a WorkSafe course, call the campus in your area or call the WCB at or call toll-free SAFE (7233). Publications and videos The WCB is one of North America s leading publishers of workplace safety materials. Many brochures, posters, and booklets are free to B.C. workers and employers. Some videos are available for purchase or loan. To receive the WCB publications catalogue, WCB video catalogue, or any publications or videos listed in the catalogues, contact the Films and Posters Section: Films and Posters Section Workers Compensation Board of B.C Elmbridge Way Richmond BC Phone: Fax: Toll free: , local 3068 Mailing address: Workers Compensation Board of B.C. PO Box 5350 Stn Terminal Vancouver BC V6B 5L5 [email protected] Resources 99

96 Prevention at Work The WCB publication Prevention at Work provides health and safety news for the employers and workers of British Columbia. It is published bi-monthly. For your free subscription to Prevention at Work, call Outside the Lower Mainland, call toll free , local Publications on the Web The Occupational Health and Safety Regulation and many other WCB publications are available at the WCB Web site: WCB library open to the public The WCB library maintains a comprehensive collection of health and safety publications. You can browse information at the library or borrow publications through your local library s interlibrary loan service Westminster Hwy Richmond BC V7C 1C6 Phone: Fax: Toll free: , local 8450 Open 8:30 to 4:30, Monday to Friday Forest Products Manufacturing Advisory Group of British Columbia The Forest Products Manufacturing Advisory Group (FPMAG) is a collaborative forum for workplace health and safety issues. It includes labour and industry representatives from the five sectors, and members from the WCB Prevention Division. The FPMAG s purpose is to develop strategies and initiatives to help industry assume responsibility for health and safety in the workplace and reduce injury, disease, and fatalities in the long term. It also coordinates and disseminates information on health and safety technology. The FPMAG publishes a newsletter and bulletins to publicize its activities, increase awareness of issues, and provide information to help industry comply with regulatory requirements. If you would like to receive copies of the newsletter and bulletins, contact one of the members of FPMAG listed below. Group Members Herb Barden Canadian Plywood Association Phone: Fax: Mike Bomberger IWA-Canada Phone: Fax: Keith Brain (Chairperson) Northern Forest Products Association Phone: Fax: Forest Products Manufacturing: Focus Report 100

97 John Brink B.C. Council of Value Added Wood Processors Phone: Fax: Doug Daniels Coast Forest and Lumber Association Phone: Fax: Dean Dobrinsky Pulp and Paper Forum Phone: Fax: Manny Gomes Workers Compensation Board of B.C. Phone: Fax: Ian May Council of Forest Industries Phone: Fax: Greg Melnechuk Pulp, Paper and Woodworkers of Canada Phone: Fax: Jim Moore Interior Lumber Manufacturers Association Phone: Fax: Jim Parker (Vice-Chairperson) IWA-Canada 2171 Phone: Fax: Dave Schaub Communication, Energy and Paperworkers Union of Canada Phone: Fax: Mike Skellet Cariboo Lumber Manufacturers Association Phone: Fax: Employers Advisers The Employers Advisers office is a branch of the Ministry of Labour. It is independent of the WCB. Employers advisers provide assistance and advice to employers on workers compensation legislation, decisions, appeals, and policies. Advisers conduct educational seminars for employers on many topics such as occupational health and safety requirements, claims management, and assessments. The Employers Advisers can be reached at three locations: Richmond Employers Advisers, Compensation Advisory Services Ackroyd Road Richmond BC V6X 3K1 Phone: Fax: Toll free: Prince George Toll free: Victoria Toll free: Workers Advisers The Workers Advisers office is also a branch of the Ministry of Labour, independent of the WCB. Workers advisers provide assistance and advice to workers who are having problems with WCB claims. The Workers Advisers can be contacted at these locations: Richmond Workers Advisers, Compensation Advisory Services Ackroyd Road Richmond BC V6X 3K1 Phone: Fax: Toll free: Kamloops Toll free: Nanaimo Toll free: Victoria Toll free: Prince George Toll free: Resources 101

98 WCB Offices Visit our Web site at Abbotsford 2774 Trethewey Street V2T 3R1 Phone Fax Burnaby Roberts Street V5G 4E1 Phone Fax Coquitlam Lincoln Avenue V3B 6B4 Phone Fax Courtenay th Street V9N 8G6 Phone Fax Cranbrook 100 7th Avenue S. V1C 2J4 Phone Fax Kamloops 321 Battle Street V2C 6P1 Phone Fax Kelowna Enterprise Way V1Y 9T5 Phone Fax Nanaimo 4980 Wills Road V9T 6C6 Phone Fax Nelson 524 Kootenay Street V1L 6B4 Phone Fax North Vancouver East 15th Street V7L 2P9 Phone Fax Prince George 1066 Vancouver Street V2L 5M4 Phone Fax Surrey nd Street V3S 8E7 Phone Fax Terrace 4450 Lakelse Avenue V8G 1P2 Phone Fax Vernon th Avenue V1T 8Y8 Phone Fax Victoria 4514 Chatterton Way V8X 5H2 Phone Fax Head Office 6951 Westminster Hwy. Richmond, BC V7C 1C6 Mailing Address: PO Box 5350 Stn Terminal Vancouver, BC V6B 5L5 Phone Toll Free SAFE (7233) After Hours Safety & Health Emergency Forest Products Manufacturing: Focus Report 102

99 8M 9/99 Printed in Canada