OSHA Inspection: FALL RIVER FOUNDRY

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $5,400 · Current $2,700 Reduced

General-duty citation text

29 CFR 1910.134(f)(2):     The employer did not ensure that an employee using a tight-fitting facepiece respirator was fit tested prior to initial use of the respirator, whenever a different respirator facepiece was used, and at least annually thereafter.    Employees required to wear N95 respirators in the grinding department have not been fit tested in over a year.    Abatement certification required per 29 CFR 1903.19(c).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $6,300 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1025(e)(1)(i):     Where any employee is exposed to lead above the permissible exposure limit for more than 30 daysper year, the employer shall implement engineering and work practice controls (including administrative controls) to reduce and maintain employeeexposure to lead in accordance with the implementation schedule in Table I below, except to the extent that the employer can demonstrate that suchcontrols are not feasible. Wherever the engineering and work practice controls which can be instituted are not sufficient to reduce employee exposureto or below the permissible exposure limit, the employer shall nonetheless use them to reduce exposures to the lowest feasible level and shallsupplement them by the use of respiratory protection which complies with the requirements of paragraph (f) of this section.    1.  The finisher working in the stand grinding area was exposed to lead dust at an 8 hour time weighted average of 0.19 milligrams per cubic meter (mg/m3), approximately 3.8 times the limit of 0.05 mg/m3; this limit is established to prevent nephrotoxicity; cumulative blood effects; cumulative neurologic effects; reproductive hazards.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    2.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 0.12 mg/m3, approximately 2.4 times the limit of 0.05 mg/m3; this limit is established to prevent nephrotoxicity; cumulative blood effects; cumulative neurologic effects; reproductive hazards.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    3.  The finisher working in the bench grinding area was exposed to copper dust at an 8 hour time weighted average of 0.47 mg/m3, approximately 9.4 times the limit of 0.05 mg/m3; this limit is established to prevent nephrotoxicity; cumulative blood effects; cumulative neurologic effects; reproductive hazards.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    29 CFR 1910.1000(e): Feasible administrative or engineering controls were not implemented to reduce employee exposure.    1.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 1.5 milligrams per cubic meter (mg/m3), approximately 1.5 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    2.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 3.7 mg/m3, approximately 3.7 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    3.  The finisher working in the bench grinding area was exposed to copper dust at an 8 hour time weighted average of 1.4 mg/m3, approximately 1.4 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    Abatement will normal be multi-step as follows:    STEP 1:  Effective respiratory protection shall be provided and used and a respiratory protection program shall be developed and implemented for exposed employees as an interim protective measure until feasible engineering and/or administrative controls can be implemented, or whenever such controls fail to reduce employee exposure to within permissible exposure limits.  Abatement date: ___________________    STEP 2:  Submit to the Area Director a written, detailed plan of abatement outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposure to hazardous substances as references in this citation.  This plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation.    1.  Evaluation of engineering/administrative control options;  2.  Selection of optimum control methods and completion of design;  3.  Procurement, installation, and operation of selected control measures; and  4.  Testing and acceptable or m0dification/redesign of controls.    All proposed control measure shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.    Thirty (30) day progress report is required during the abatement period.      STEP 2 abatement date is ____________________________    STEP 3:  Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.    STEP 3 abatement date is ____________________________

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $2,700 · Current $1,350 Reduced

General-duty citation text

29 CFR 1910.141(g)(2):     Eating and drinking areas. No employee shall be allowed to consume food or beverages in a toilet room nor in any area exposed to a toxic material.    Copper dust was found on all 5 surfaces sampled in the employee lunch room.  Surfaces included: 2 table tops, a microwave faceplate, a refrigerator handle, and soda dispensor buttons.    Abatement certification required per 29 CFR 1903.19(c).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $3,600 · Current $0 Reduced

General-duty citation text

29 CFR 1910.178(l)(1)(i):     The employer did not ensure that each powered industrial truck operator was competent to operate a powered industrial truck safely.    Employees are operating forklifts in manual pour off and manual shakeout without receiving training on safe forklift operation.    Abatement certificaiton required per 29 CFR 1903.19(c).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $6,300 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1025(i)(4)(iv):     The employer did not assure that employees did not enter lunchroom facilities with protective workclothing or equipment unless surface lead dust had been removed by vacuuming, down draft booth, or other cleaning method.    Stand grinding and bench grinding employees were entering the lunchroom wearing lead contaminated clothing.    Abatement documentation required per 29 CFR 1903.19(d).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $5,400 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1025(m)(2)(i):     The employer did not post the following warning signs in each work area where the PEL for lead is exceeded:  WARNING, LEAD WORK AREA, POISON, NO SMOKING OR EATING.    No lead warning signs are posted in the finishing department where air monitoring determined that lead levels exceeded the PEL.    Abatement certification required per 29 CFR 1903.19(c).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $2,700 · Current $1,350 Reduced

General-duty citation text

29 CFR 1910.1200(h)(1):     Employees were not provided information and training as specified in 29 CFR 1910.1200(h)(2-3) on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard was introduced into their work area.    Employees working with silica sand in the foundry were not trained on silica hazards prior to beginning work with the employer.    Abatement certification required per 29 CFR 1903.19(c).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $12,600 · Current $6,300 Reduced

General-duty citation text

29 CFR 1910.1000(a)(2):     Employee(s) were exposed to an airborne concentration of copper dust listed in Table Z-1 in excess of 1.0 mg/m3 (milligrams per cubic meter) as an 8 hour time weighted average concentration.    Fall River Foundry was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 313132789, citation number 1, item number 1a and was affirmed as a final order on July 28, 2010, with respect to the workplace located at 670 S. Main St, Fall River, WI 53932.    1.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 1.5 milligrams per cubic meter (mg/m3), approximately 1.5 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    2.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 3.7 mg/m3, approximately 3.7 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    3.  The finisher working in the bench grinding area was exposed to copper dust at an 8 hour time weighted average of 1.4 mg/m3, approximately 1.4 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    Abatement documentation required per 29 CFR 1903.19(d).

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1000(e):     Feasible administrative or engineering controls were not implemented to reduce employee exposure.    Fall River Foundry was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 313132789, citation number 1, item number 1b and was affirmed as a final order on July 28, 2010, with respect to the workplace located at 670 S. Main St, Fall River, WI 53932.    1.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 1.5 milligrams per cubic meter (mg/m3), approximately 1.5 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    2.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 3.7 mg/m3, approximately 3.7 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    3.  The finisher working in the bench grinding area was exposed to copper dust at an 8 hour time weighted average of 1.4 mg/m3, approximately 1.4 times the limit of 1 mg/m3; this limit is established to prevent eye, upper respiratory tract irritation; dermatitis; rare interstitial lung disease/ pulmonary fibrosis.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    Abatement will normall be multi-step as follows:    STEP 1:  Effective respiratory protection shall be provided and used and a respiratory protection program shall be developed and implemented for exposed employees as an interim protective measure until feasible engineering and/or administrative controls can be implemented, or whenever such controls fail to reduce employee exposure to within permissible exposure limits.  Abatement date: ___________________    STEP 2:  Submit to the Area Director a written, detailed plan of abatement outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposure to hazardous substances as references in this citation.  This plan shall include, at a minimum, target dates for the following actions which must be consistant with the abatement dates required by this citation.    1.  Evaluation of engineering/administrative control options;  2.  Selection of optimum control methods and completion of design;  3.  Procurement, installation, and operation of selected control measures; and  4.  Testing and acceptable or m0dification/redesign of controls.    All proposed control measure shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.    Thirty (30) day progress report is required during the abatement period.      STEP 2 abatement date is ____________________________    STEP 3:  Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.x    STEP 3 abatement date is ____________________________

Issued

Feb 6, 2012

Abate by

Feb 16, 2012

Penalty

Initial $12,600 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1025(c)(1):     The employer did not assure that no employee was exposed to lead at concentrations greater than fifty micrograms per cubic meter of air (50 ug/m(3)) averaged over an 8-hour period.    Fall River Foundry was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 310768619, citation number 1, item number 3c and was affirmed as a final order on January 28, 2009, with respect to the workplace located at 670 S. Main St, Fall River, WI 53932.    1.  The finisher working in the stand grinding area was exposed to lead dust at an 8 hour time weighted average of 0.19 milligrams per cubic meter (mg/m3), approximately 3.8 times the limit of 0.05 mg/m3; this limit is established to prevent nephrotoxicity; cumulative blood effects; cumulative neurologic effects; reproductive hazards.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    2.  The finisher working in the stand grinding area was exposed to copper dust at an 8 hour time weighted average of 0.12 mg/m3, approximately 2.4 times the limit of 0.05 mg/m3; this limit is established to prevent nephrotoxicity; cumulative blood effects; cumulative neurologic effects; reproductive hazards.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    3.  The finisher working in the bench grinding area was exposed to copper dust at an 8 hour time weighted average of 0.47 mg/m3, approximately 9.4 times the limit of 0.05 mg/m3; this limit is established to prevent nephrotoxicity; cumulative blood effects; cumulative neurologic effects; reproductive hazards.  The sample was collected on October 20, 2011 during a 480 minute sampling period.    Abatement documentation required per 29 CFR 1903.19(d).