Safety & Health
Bechtel Cites Error It Sees as Trigger Cause of Texas Project's Triple Fatality
A photo supplied by Bechtel depicts what it said was an example of a correctly set bracket fastener for a formwork climbing system of the type used at a Port Arthur, Texas, LNG export terminal project.
Bechtel says an improperly secured bracket connection between a climbing form system and a concrete tank being constructed led to the accident that killed three employees in April on an estimated $13-billion LNG export terminal project in Port Arthur, Texas.
The announcement of the suspected cause comes as part of a broader commentary on the incident by Craig Albert, Bechtel's corporate president and Paul Marsden, president of its energy unit. Since the accident, Bechtel officials have discussed the tragedy in terms of what they say is a larger soul-searching effort about its safety practices.
Killed in the accident were Felix Jose Lopez, 42; Felipe Mendez, 25; and Reginald Magee, 41. Lopez and Mendez were pronounced dead at the scene. Magee was taken to a local hospital where he died from his injuries. Two other injured workers involved in the accident were treated and are expected to make a full recovery, authorities said.
"The overwhelming sense of shock and grief we felt in that moment hasn’t faded," the two said in a prepared statement.
The technical information released today is unusual in that the final U.S. Occupational Safety and Health Administration investigation is not yet public, and there are two still pending state lawsuits against the contractors by families of the workers and by accident survivors.
In at least one suit, Bechtel required the plaintiffs to take part in an arbitration over the claims as required in the workers' employment agreements.
OSHA's investigation result and possible workplace safety penalties are usually released six months after an accident.
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San Diego-based Sempra Infrastructure, which awarded Bechtel the project EPC contract, is an owner and also a defendant in the lawsuits. The first phase, estimated at $13 billion and expected to have 13-million ton-per-year production capacity, is set to complete its two trains in 2027 and 2028. Sempra last year also announced Bechtel as EPC contractor for the project's estimated $12-billion second phase that will have about the same capacity, with final investment decision announced last month..
What happened at the site is known in general terms. Three site workers fell an estimated 65 ft to 85 ft in what was described as a "tank jump-form system incident” after a layer of scaffolding, part of the jump-form system, connected to a concrete tank failed.
In a query to Bechtel, ENR asked whether its staff was in control of the formwork and its bracket connections or if it considered other employers to be culpable—a key point that could affect lawsuit outcomes. ENR also requested images of the failed connection itself, if any was available that could be released. The company said it was unable to comment or provide the requested image.
Spreader bar and cables above tank forming system work surface, with notes in red made by Bechtel's attorney. Source: Texas court filing.
But Bechtel did provide a more detailed narrative about how it saw the events in the message from Albert and Marsden.
It said that formwork jumping involves lifting the multilayered formwork system and work platform and resetting it higher on the tank to tie the reinforcing steel and place the next elevation of the concrete wall.
Crew members "had successfully jumped and set eight sections during their shift and was setting the last section at the time of the incident," Bechtel stated.
The company stated that each formwork panel has two vertical brackets, each connected to a cone screw that secures the panel to the tank wall.
"Our investigation determined that, while setting the final section, the bracket connection on the formwork was not securely attached to the cone screw, a form of steel bolt with an integrated washer," said Bechtel, as seen in the photo at the top of the article. The cone screw is screwed into an embed [shown in green], which is cast into the concrete wall of the tank, the firm added.
