Category: Case Studies

Grain Elevator – OSHA Citation

Haag was asked to evaluate design and installation of a cross-flow grain dryer at an Ohio grain elevator, and address the merits of an OSHA citation related to installation and safety, & evaluate compliance with 29 CFR.

A natural-gas fired, choke-fed, cross-flow dryer was originally installed by the manufacturer in 1997 and had remained substantially unchanged. After a brief visit, OSHA issued citations which stated that the involved dryer was not equipped with “controls that automatically stopped the incoming grain to the dryer when a high temperature condition was detected.” Further, OSHA added that “it was clear the equipment [had] the necessary components to be installed to meet the standard… but it was discovered that the alarm sensor… was never installed.”

Haag reviewed installation and operator manuals provided with the grain dryer and determined that the involved dryer could be installed in one of two configurations – a choke-fed configuration and a reversing-slide gate configuration. For the former, a positive shutdown mechanism for the incoming grain elevator leg was not recommended by the manufacturer. Grain flow into the dryer was stopped by shutting down the discharge metering system during a high temperature alarm, causing the incoming grain to bypass the dryer spout and return to storage. Since the automatic shutdown of the discharge metering system effectively stopped the flow of grain into the dryer, we concluded that the automatic shutdown complied with the requirements of 29 CFR 1910.272. Site visits by Haag and the dryer manufacturer independently verified that all required sensors and controls were properly installed on the involved dryer.

Further, Haag reviewed national consensus standards for emergency shutdowns published by the National Fire Protection Association (NFPA). A key distinction between the NFPA and 29 CFR 1910.272 was that the NFPA required the sensors to “stop the flow of product out of the dryer” while 29 CFR required sensors to “stop the grain from being fed into the dryer.” Haag Engineering evaluated the merits of each standard using Failure Mode and Effects Analysis and other techniques and concluded that the NFPA standard provided greater protection from the anticipated hazards than 29 CFR 1910.272. According to Appendix A of 29 CFR 1910.272, compliance with a national consensus standard that provides equal or greater protection than 29 CFR 1910.272 is considered compliance with the corresponding requirements.

We published a report addressing the alleged installation issues and safety requirements of both 29 CFR and the NFPA. Our analyses had shown that the involved dryer complied with both standards. The matter was ultimately resolved after all citations against the grain elevator were removed

Grain Explosion Evaluation

A large grain dust explosion occurred at a grain company facility. The explosion severely damaged three connected silos and injured six workers, as employees were loading rail cars when the explosion happened, and sections of the bins toppled onto the rai.

On August 13, 2014, a large grain dust explosion occurred at the Coshocton Grain Company facility in Coshocton, Ohio. The explosion severely damaged three connected silos and injured six workers. Employees were loading rail cars when the explosion happened around 4 pm, and sections of the bins toppled onto the rail cars.(1)

The 60-year-old Coshocton Grain facility was a 2.5-million-bushel capacity grain receiving, drying, and storage facility that included three slip-formed concrete storage houses standing more than 100 feet above grade at the bin deck. A single gallery spanned across all three houses; two of the houses had head houses. A tunnel network connected all three grain houses in the basement, and one of the houses to a truck dump building and to several silos across railroad tracks to the south. South of the railroad tracks were five additional concrete silos, four steel storage bins, and several small buildings.

Seven bucket elevators, 12 drag conveyors, 11 belt conveyors, two screw augers, and one tripper directed the flow of grain throughout the facility. In general, the equipment in the basement and ground-level directed flow of grain away from the dumps and bins, and to the boots of the elevators. Elevated equipment directed flow away from the elevator legs to the various silos, bins, dryers, and load out areas of the facility. There were also three dust collectors, a dryer, a truck scale, and a continuous flow scale.

Haag responded to determine the origin and cause of the explosion, which included coordinating with OSHA representatives and salvage efforts.

The explosion caused a large area of the middle house to blowout and the head house to fall to the ground and damage several railcars and railroad tracks. Haag’s original scope expanded to include documentation of the explosion site using 360° photography and scanning (3D laser scanning), evaluation of structural and mechanical damage caused by the explosion, and a cost estimate of the explosion-related damage.

SOURCE (1) NO GRAIN, NO GAIN: COSHOCTON GRAIN, FARMANDDAIRY.COM; HTTPS://WWW.FARMANDDAIRY.COM/TOP-STORIES/NO-GRAIN-NO-GAIN-NEARLY-A-YEAR-AFTER-A-DEVASTATING-EXPLOSION-COSHOCTON-GRAIN-IS-COMING-BACK/265567.HTML, JUNE 2015.)

Involved Experts:

John Z. Wlascinski, Principal Engineer, Houston Branch Manager, Board Chairman

Ground Surface Dropout at Residence

Basic Fact Pattern

During a site stabilization, a surface dropout occurred below the residential structure causing additional damage to the foundation and walls.

Investigative Actions Taken

Haag performed a geotechnical subsurface evaluation of a residence related to possible sinkhole activity. Our study of the property involved exploratory drilling and sampling, shallow excavation, a geophysical survey and laboratory testing. Our findings revealed highly weathered limestone at depth and formed cavities and voids from soil raveling associated with sinkhole activity.

Determinations Made

Haag recommended a program of deep compaction grouting and shallow chemical grouting to stabilize the building pad. During stabilization, several surface dropouts occurred. Haag quickly responded to develop plans for stabilizing the ground and residential structure. Haag monitored the filling of voids below the foundation and slab with a cement slurry and rapidly implemented a grouting program to treat raveled soils and limit property damage.

Involved Expert:

George Stepanchak, P.E., Engineering and Geotechnical Manager

Hoover Dam By-Pass Bridge Collapse

The Hoover Dam’s By-Pass lifting system, a luffing cableway supported by four towers, collapsed during high winds.

The Hoover Dam By-Pass Bridge was part of the new alignment of U.S. Highway 93 across the Black Canyon between Arizona and Nevada and was located approximately 1,500 feet downstream of Hoover Dam. Total length from abutment to abutment was approximately 1,090 feet. The structure was the first concrete-steel composite arch bridge built in the United States and includes the longest cast-concrete arch in the Western Hemisphere. The Obayashi Corporation and P.S.M. Construction USA, Inc. Joint Venture (Obayashi/PSM JV) was awarded the bridge construction contract by The Federal Highway Administration (FHWA). HDR Engineering, Inc., and T.Y. Lin International were the bridge design team.

For construction of the bridge, the By-Pass lifting system was a luffing cableway as defined by the American Society of Mechanical Engineers (ASME) B30.19 – Cableways. Four lattice towers, each approximately 330 feet tall, were erected on either side of the Colorado River immediately south of the Hoover Dam. Distance between the opposing towers (span) was approximately 2,500 feet. The two cableways extended parallel and along the centerlines of the double highway lanes of the new bypass bridge. Each tower could lean (luff) in the north/south direction to provide lifting capabilities for the load block to reach the entire width of each of the double highway lanes. Lower and upper load blocks were supported by a carriage that was positioned along the spanned length by inhaul and outhaul ropes on the track cables (gut lines).

During high winds on September 15, 2006, the Nevada South tower buckled and collapsed. During the collapse, the falling sections severed multiple support cables of the Nevada North tower causing it to fall to the north. The resulting collapse of both Nevada towers imparted dynamic loading to the two Arizona towers, causing both to fall westward toward the Black Canyon of the Colorado River.

Haag Engineering Co. was retained to determine factors causative of the collapse and evaluate duties and responsibilities of the parties involved in the design, erection and use of the specialized equipment. During recovery efforts, Haag assisted in the design/evaluation of a new cableway system, erection and load testing. The Haag team was assigned to the project from collapse on September 15, 2006 until the connection of the arches in 2010.

The Hoover Dam By-Pass Bridge was sucessfully completed after this set-back, and officially named the “Mike O’Callaghan–Pat Tillman Memorial Bridge”. Opening ceremonies were held on October 19, 2010. The bridge has been a vital to improving traffic on Interstate 93, between Phoenix and Las Vegas and between the United States and Mexico, ever since.

Restoring a Fire-Damaged High-Rise

Fire damaged three floors of an apartment tower; smoke and water damaged the rest. Haag consultants created the plan for setting things right, and for keeping the loss from growing in scope and cost.

The direct fire damage was extensive — three of the nine floors in a Little Rock residential high-rise — and the water and soot damage was comprehensive. All nine floors required expert evaluation and restoration. Haag Construction Consultants became the central figures, working with the adjuster, contractors, and municipal building officials to determine the scope, cost, and timeline for putting things right. That required careful analysis of what could be repaired, what required replacement, and what each would cost. In addition, our Haag consultants were asked to identify potential environmental exposures, especially with regard to indoor air quality and possible improper mitigation practices. Not only did Haag give all the interested parties a complete, clear picture of the loss, we also helped identify tasks that required urgent attention to prevent the loss from growing in scope and costs.

A Storm Overwhelms Dormitories’ Drainage Systems

When the storm drains around the dormitories at a southeastern college proved inadequate in a heavy storm, water entered several of the buildings, damaging flooring and drywall. An inspection by Haag Construction Consultants established what needed to be done to restore the dorms. Then, during the restoration project, a new problem turned up: The flooring material and mastic contained asbestos. The Haag consultants arranged for an abatement contractor to perform the asbestos abatement. Despite this unforeseen complication and the delay it caused, Haag’s oversight helped the college complete the dorm reconstruction in a timely manner.

Construction Consulting Post-Hurricane

The 2017 storm year began with Harvey, the stubborn gulf storm which camped out over Houston and the entire coast of Texas for 7 days in August. Irma and Maria then dealt back-to-back blows to the Caribbean, with property claims activity extending through the Keys into Central Florida.

Haag’s Construction Consulting (HCC) business unit has received of a great deal of activity in all areas of the US affected by the heightened 2017 season. Years out from these storms, Haag Consultants continue to receive new assignments weekly. In addition to our 2017 hurricane work across the mainland, Puerto Rico assignments have continued at a very steady pace. We are now progressing from the initial damage assessment phase into the controversy and litigation phase.

Haag Construction Consulting’s work in Puerto Rico has included hospitals, shopping malls, high-rise office buildings, resort hotels, retail centers, government facilities, and mid and high-rise condos. As with any coastal vacation area, Puerto Rico is heavily populated with mid- and high-rise condos, apartments, and resort hotel properties.

Multi-family or commercial property assignments usually involve Construction Consulting inspection teams of four to eight consultants for anywhere from two to six days to carry out the initial site inspection activities. As the site inspection is concluded, our teams then move to the production of repair estimates and reports, which involves sorting through thousands of site photos and hundreds of pages of scope notes. We translate those notes and photos into a very thorough, supported scope analysis and repair estimate.

The team at Haag Construction Consulting’s work product and quality has led to satisfied clients, which in turn has created additional work in Puerto Rico, and all 2017 hurricane-effected areas.

By Brandon Alaniz, Senior Construction Consultant

Brandon Alaniz is an experienced construction consultant, with more than 15 years in the construction industry. He is responsible for maintenance, and completion of all consulting services and related work product. His emphasis is building reconstruction, restoration, equipment and machinery cost, and remediation cost for the insurance industry. Preparation of construction loss estimates and restoration / remediation management services for losses that are either repaired by the owners and need constant supervision to expedite or losses that require this service to fast-track a project without the need of a general contractor, to insure the favorable / equitable conclusion of a loss. Experience in many forms / types of construction and restoration including; multi-family dwellings, educational, municipal, hotel/motel, and multi-story

Hurricane Shelter Collapse

Haag Engineering was asked to determine the cause of collapse of a hurricane shelter, determine responsible party with respect to subrogation, & evaluate the remaining structure with respect to repairability.

The metal building structure was an indoor sport/event arena that doubled as a hurricane shelter. Approximately 1,400 people had flocked to the shelter for safety before the storm. The metal roof system peeled away as the storm neared, causing most of the building to collapse. All 1,400 occupants survived due to their retreat below the concrete bleachers. Haag Forensic Engineers were called out to determine the primary cause of the collapse, determine who was responsible with respect to subrogation, and to evaluate the remaining structure with respect to reparability. We examined the structure, stewarded required evidence retained for all parties, and identified building conditions that led to the collapse. Our conclusions were provided via open forum presentation during mediation. The accuracy, detail, and reporting of our conclusions in a simple yet complete presentation enabled all parties to quickly understand the facts of the collapse and come to a mutual financial agreement without litigation. The structure was reconstructed after settlement was achieved.

Hyatt Regency Walkway Collapse

Haag Engineer E. Earle Walters discusses the investigation of the collapse of two walkways at a Hyatt Regency hotel.

Imperial Sugar- Sugar Dust Explosion and Fire

A massive explosion and ensuing fire destroyed much of the Imperial Sugar processing facility. Haag engineers were asked to evaluate the scope and cost of damage, monitor the repairs, and segregate upgrades and improvements.

by John D. Stewart, P.E., Principal Engineer Emeritus

Around 7:00 am on February 7, 2008, a massive explosion occurred in the center of the Savannah Foods/Imperial Sugar facility, destroying or extensively damaging all three sugar silos and the packaging buildings that surrounded the silos. Sugar dust was believed to have been ignited by operating machinery. Many buildings outside the center of the plant also was extensively damaged. Investigations by government agencies as well as private experts concluded that the event was caused by an explosion of sugar dust followed by a fire wherein the sugar in the silos and throughout the area burned. Tragically, 14 individuals were killed in the blast and some 40 others were burned or injured.

Savannah Foods in Port Wentworth, Georgia, was founded in 1915 by Benjamin Alexander Oxnard and Richard H. Sprague when they moved their entire sugar refining operation, including more than 300 employees and their families, from St. Mary’s Parish in Louisiana to Port Wentworth. The refinery took in raw sugar and processed it into refined sugar and various other sugar products. The Savannah Sugar Refinery began melting sugar on July 7, 1917. In 1997, Imperial Sugar Corporation acquired Savannah Foods & Industries, Inc., which at the time was the second largest sugar refiner in the industry. Savannah Foods & Industries marketed its sugar under the Dixie Crystals® brand.

The Port Wentworth refinery included many large buildings, various tanks, and additional equipment for processing the sugar. Sugar was brought into the facility by ship and sent out by rail, truck, and ships. Among the facilities were three very large reinforced concrete silos located in the center of the packaging and storage area and used for storage of bulk refined sugar. These silos, constructed in 1935, were approximately 130 feet tall by 40 feet in diameter arranged in an east-west line and were capable of holding about 3 million pounds of sugar each. A large 4-story building to the north was the North Packaging Building. Another 4-story building to the south was the South Packaging Building. North and South Palletizing areas were to the west of the silos. The main refining and raw sugar storage facilities were east of the silos. Other buildings were south of the silo/packaging area.

Following the February 2008 explosion, Haag engineers were engaged by the insurers to evaluate the scope of damage and cost of repairs to the facility resulting from the event. Haag also monitored the repair work during the several year period of restoration. Haag’s role beyond evaluation of the scope of damage was to monitor and separate extensive upgrades of the rebuilt facility from needed repairs. The extensive upgrades of the facility took it from an old processing unit to a state-of-the-art processing and packaging plant.

Haag engineers were on site from shortly after the explosion until the repairs were completed and the plant restarted in late 2009. Haag was closely involved in the evaluation of the scope of damage. Knowing that the facility would be extensively modified during the restoration it was critical to prepare a detailed scope of work including estimates of repairs for facilities that would not be rebuilt in kind. Haag also was closely involved in all discussions about all changes, extensive upgrades, and reconfigurations of the facility to ensure that costs charged to the insurers of the facility were fair and represented the costs to restore an equivalent facility despite the many changes.

In summary, a massive explosion and ensuing fire destroyed the entire packaging and bulk loading facilities as well as damaging the sugar refining, electrical power and steam facilities, and storage warehouses and bulk silos. Haag engineers were called in to evaluate the complete scope of damage to the facility. Then, we developed detailed cost figures for in-kind restoration of the facility. Finally, we monitored restoration work during the two-year work period to segregate all upgrades and improvements included with the actual costs. Haag engineers were involved in evaluating damage to structural, mechanical, electrical, and process equipment. Haag prepared detailed cost estimates for all phases of the work.

John D. Stewart, P.E., is Principal Engineer Emeritus at Haag Engineering Co. and served as Haag’s President for more than 30 years (1982 – 2014). Mr. Stewart has been with Haag Engineering Co. since 1969. His engineering expertise includes evaluating and determining the scope of damage and repair options following failures, including at industrial plants, oil refineries, chemical plants. He has analyzed electrical failures, lightning damage, and electronic and computer equipment failures.

Mr. Stewart graduated from the University of Texas at Arlington with a Bachelor of Science degree in Electrical Engineering. He is a licensed professional engineer in the states of Texas and Arizona, and a member of the Institute of Electrical and Electronic Engineers (IEEE), the American Institute of Chemical Engineers (AIChE), the National Fire Protection Association (NFPA), the International Association of Arson Investigators (IAAI), the National Society of Professional Engineers (NSPE), and the Texas Society of Professional Engineers.

BELOW, A 2008 IMAGE AFTER THE EXPLOSION AND A 2019 OBLIQUE IMAGE OF THE SAME AREA (IMAGES 1 & 2). THE CENTERS OF BOTH IMAGES COVER MOST OF THE AREAS OF MAJOR DAMAGE.