FREMONT, OH – A federal workplace safety investigation into how a 25-year-old manufacturing worker suffered serious arm burns in February that required hospitalization, determined his Ohio employer failed to follow required federal safety standards that might have prevented the incident.

OSHA opened an inspection of International Cushioning Co. in Fremont on Feb. 10, 2022, after learning of the injury and receiving a referral by the local fire department alleging fire hazards due to poor housekeeping of combustibles and flammables.

OSHA learned the worker was removing polyethylene foam from an extruding machine when a static discharge ignited isobutane, a colorless, flammable gas released in the production process. The heated foam melted on the employee’s arm, causing second-degree burns.

Inspectors also found industrial fans positioned on the foam line were not properly rated for use in hazardous atmospheres, and that the employer failed to provide workers with spark-resistant hand tools – violations that exposed workers to potential ignition hazards.

The company also failed to provide adequate protective equipment for the workers’ hands, arms, and feet.

OSHA Area Director Todd Jensen said, “During our initial inspection in Fremont, inspectors found additional issues and identified more than two dozen violations and related hazards the company must address before other employees are harmed.”

The February inspection also led OSHA to cite the company for:

A March 2 health inspection found unsanitary conditions and process safety management violations. Inspectors also learned the company did not have a hearing conservation program or an emergency action plan.

In all, OSHA issued citations for 25 serious safety and health violations and proposed $177,950 in penalties.

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