OSHA Inspection: U S CASTING COMPANY

Issued

Aug 15, 2005

Abate by

Sep 17, 2005

Penalty

Initial $7,000 · Current $4,500 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not
furnish employment and a place of employment which were free from
recognized hazards
that were causing or likely to cause death or serious physical harm to
employees in that
employees were exposed to water/metal explosions from inadequate furnace
rebuilding and
sintering procedures:
a) On February 22, 2005, a worker was fatality burned during sintering
operations on
the Pillar MK8 induction furnace. The ground leak detection system was not
installed
properly and the temperature of the heat was not monitored during the
sintering process. The
furnace bridged and exploded with molten metal erupting onto the employee.
b) On June 24, 2005, The Inductotherm VIP Dual Trak 1500-5CR induction
furnace
ruptured during the sintering process. The wrong type of refractory
material was used to line
the furnace and the ground leak detection system was repeatedly
overridden.
The furnace
exploded with molten metal erupting out and through the bottom side onto
the floor.
Among other means, acceptable and feasible means of abatement include, but
are not limited
to the following:
1. Follow the furnace and refractory manufactures' recommendations for
furnace rebuilding;
2. Install the ground leak detection system in accordance with
manufactures'
recommendations;
3. Monitor the metal temperature continuously during sintering operations;
4. Follow the furnace manufactures' recommendations for preventing
bridging;