Email Jim at jim.thompson@ipulpmedia.com
I must have told this story before, but it is worth telling again.
We were rebuilding a paper machine on an accelerated schedule. It was a massive rebuild. I was the Owner's representative on night shift. We had about 75 jackhammers and 2 hoe rams operating on each shift, all inside the paper machine building. The noise was unimaginable.
One evening, one of our engineers, the contractor's rep, and I were in the basement under the wet end. It had concrete block walls, and the wet end was U-shaped with no exit at the wet end. The three of us heard some heavy lumber falling from the dryer cans above us.
We started running towards the dry end. The other two were pushing off me. I got hit in the calf with a 4 x 4 about 12 feet long. There was a bunch of plywood and other 4 x 4's coming down through the dryers, but fortunately we did not get hit. I was on the ground, and they would not let me get up until the EMT's came. As an aside, one of the EMT's broke a finger coming to my rescue. I didn't have any more than a bruise and denied any further treatment.
In a few minutes, we all went back to work. Dummies that we were, we did not think about the source of the lumber.
About forty-five minutes later, someone happened to go up to the top of the dryer section. There was a worker up there hanging onto the overhead framework of the dryer hood and about to lose his grip. It was about forty feet to the ground, coming down through the dryers. He had been yelling and screaming but no one had heard him due to the ambient noise of the jackhammers. Thankfully, they got him down with no significant injuries. It was the lumber that he was standing on that had come down through the dryers.
Think about how else you could have a safety accident related to noise such as this one. Trains switching is one thing. Any place there is loud ambient noise is another.
What are some solutions? I think using the "buddy system" so that no one is working in such a place by themselves is a place to start.
Be safe and we will talk next week.
For a deeper dive, go here.
Industrial Safety Case Study: The Impact of High Ambient Noise
This study guide examines the safety implications of high-decibel environments within industrial settings, using a specific account of a paper machine rebuild as the primary case study. It explores how extreme noise can mask critical warning signs and prevent emergency communication, leading to life-threatening situations.
Short-Answer Quiz
Question 1: Describe the environmental conditions and the scale of the project during the incident described by Jim Thompson.
Question 2: Who were the three individuals located in the basement under the wet end when the lumber began to fall?
Question 3: What was the physical configuration of the basement area where the men were working?
Question 4: Identify the specific machinery and quantities responsible for the "unimaginable" noise levels in the building.
Question 5: What specific injury did Jim Thompson sustain during the initial incident, and what was the outcome of his medical assessment?
Question 6: What irony or secondary incident occurred involving the emergency responders called to the scene?
Question 7: Following the initial incident where lumber fell, how did the workers react, and what critical oversight did they commit?
Question 8: Provide details regarding the worker discovered 45 minutes after the initial incident occurred.
Question 9: Explain the primary reason why the worker's attempts to call for help were unsuccessful.
Question 10: According to the text, what is a primary solution for ensuring safety when personnel must work in high-noise environments?
Answer Key
Answer 1: The project involved a massive rebuild of a paper machine conducted on an accelerated schedule. The environment was characterized by extreme noise generated by heavy machinery operating on every shift.
Answer 2: The three individuals present were Jim Thompson (the owner's representative on the night shift), one of the project engineers, and a representative for the contractor.
Answer 3: The basement featured concrete block walls and a U-shaped configuration at the wet end. Notably, this specific area of the wet end had no exit, creating a potential trap for workers.
Answer 4: The noise was produced by approximately 75 jackhammers and two hoe rams operating simultaneously on each shift within the paper machine building.
Answer 5: Thompson was hit in the calf by a 12-foot-long 4x4 piece of lumber. Despite the impact, he suffered only a bruise and declined further medical treatment after an initial assessment.
Answer 6: While coming to Thompson's rescue, one of the Emergency Medical Technicians (EMTs) suffered a broken finger. This resulted in the rescuer sustaining a more severe injury than the person they were sent to treat.
Answer 7: The workers went back to work within a few minutes of the incident. The text notes they acted as "dummies" because they failed to consider or investigate the actual source of the falling lumber.
Answer 8: A worker was found 40 feet above the ground, clinging to the overhead framework of the dryer hood. He had been standing on the lumber that fell and was about to lose his grip when he was finally discovered.
Answer 9: Although the worker had been yelling and screaming for help, the ambient noise from the jackhammers was so loud that no one in the vicinity could hear him.
Answer 10: The author suggests implementing a "buddy system." This protocol ensures that no individual is left to work in a high-noise or hazardous area by themselves, providing a redundant layer of safety and observation.
Essay Format Questions
- The Hidden Dangers of Noise: Analyze how high ambient noise functions as a "silent" hazard in industrial settings. Use the text to explain how auditory masking can transform a localized accident into a life-threatening emergency.
- Human Error and the "Accelerated Schedule": Discuss the relationship between the project's "accelerated schedule" and the workers' failure to investigate the source of the falling lumber. How does pressure to perform affect safety-related decision-making?
- Physical Barriers and Egress: Evaluate the significance of the basement's U-shaped design and lack of exit. How do architectural or layout constraints contribute to the severity of industrial accidents?
- The Role of Emergency Services: Reflect on the incident involving the EMT's broken finger. Discuss the risks inherent in emergency response within active construction zones and how those risks can be mitigated.
- Implementing the Buddy System: Based on the author's suggestion, develop a rationale for why the "buddy system" is an effective countermeasure against the specific dangers presented by high-noise environments.
Glossary of Key Terms
Term Definition
4 x 4 A standard piece of heavy lumber measuring approximately four inches by four inches in thickness.
Accelerated Schedule A project management approach where construction or rebuilding is performed faster than usual, often involving more labor or equipment.
Ambient Noise The background sound pressure level at a given location, in this case, the extreme noise generated by construction tools.
Buddy System A safety procedure where two people work together as a single unit so that they can monitor and help each other.
Dryer Cans / Dryer Section The portion of a paper machine where moisture is removed from the paper; in this text, it refers to the high structure from which the worker nearly fell.
Hoe Ram A powerful percussion hammer attached to an excavator used for demolishing concrete or rock.
Jackhammer A pneumatic or electro-mechanical tool that combines a hammer directly with a chisel, used here for the paper machine rebuild.
Owner's Representative An individual or firm hired by the project owner to manage the project and ensure it is completed according to specifications.
Paper Machine An industrial machine used in the manufacturing of paper; it consists of several sections including the "wet end" and the "dryer section."
Wet End The beginning of the paper machine where the wood fiber and water slurry are processed into a web of paper.
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