OSHA Inspection: BRILLION IRON WORKS

Issued

May 3, 2012

Penalty

Initial $3,400 · Current $3,400

General-duty citation text

29 CFR 1910.22(b)(1): Aisles and passageways were not kept clear and in good repair, with no obstruction across or in aisles that could create a hazard:    a)  On 12/13/11, the raised expanded metal walk platform for the Mold Blower Iron Pourers had gaps between the sections and the sections meet at different hieghts. The gaps and sections not meeting at equal heights create tripping hazards for the employees moving ladles of molten iron.         NO ABATEMENT DOCUMENTATION OR ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Aug 13, 2013

Penalty

Initial $5,000 · Current $5,000

Hazardous substances 8110

General-duty citation text

29 CFR 1910.95(b)(1): When employees were subjected to sound exceeding those listed in Table G-16, feasible engineering controls were not utilized:    a)  On 12/08/11, the Plant #2 Disa Shakeout employee was exposed to 1507% of the permissible noise exposure over a 505 minute time period. 1507% is equivalent to an 8 hour time weighted average of 109.2 dBA.    b)  On 12/08/11, the Plant #2 BMD Shakeout employee was exposed to 518% of the permissible noise exposure over a 486 minute time period. 518% is equivalent to an 8 hour time weighted average of 101.8 dBA.    c)   On 12/08/11, the Plant #2 BMD Shakeout employee was exposed to 280% of the permissible noise exposure over a 468 minute time period. 280% is equivalent to an 8 hour time weighted average of 97.6 dBA.    d)  On 12/08/11, the Plant #2 Disa Shakeout employee was exposed to 405% of the permissible noise exposure over a 496 minute time period. 405% is equivalent to an 8 hour time weighted average of 99.9 dBA.    e)  On 12/14/11, a Stand Grinder employee was exposed to 317% of the permissible noise exposure over a 497 minute time period. 317% is equivalent to an 8 hour time weighted average of 98.0 dBA.    f)  On 12/14/11, a Swing Grinder employee was exposed to 356% of the permissible noise exposure over a 481 minute time period. 356% is equivalent to an 8 hour time weighted average of 99.1 dBA.    g)  On 01/04/12, a Plant #1 Shakeout employee was exposed to 235% of the permissible noise exposure over a 422 minute time period. 235% is equivalent to an 8 hour time weighted average of 97.1 dBA.    h)  On 01/18/12, a Plant #1 Shakeout employee and Impactor Operator was exposed to 569% of the permissible noise exposure over a 491 minute time period. 569% is equivalent to an 8 hour time weighted average of 102.3 dBA.    Feasible engineering controls may include, but are not limited to, the following:    1)  Apply vibration dampening material to cooling tunnels of the Plant #1 Disa, Plant #2 Disa and the Plant #2 BMD.    2)  Apply vibration dampening material to Shakeout tables of the Plant #1 Disa, Plant #2 Disa and the Plant #2 BMD.    3)  Redesign the Plant #2 Disa cooling tunnel gate so materials do not hang up on it and it can remain in the down position for more time.    4)  Install a gate between the cooling tunnel and shakeout area to reduce the opening on the Plant #1 Disa and the Plant #2 BMD.    5)  Install mufflers to the air exhausts of the swing grinders and the impactors.    6)  Install noise dampening materials on the vertical hard surfaces near the stand grinder work stations.    7)  Install noise dampening curtains around stand grinder work stations that currently do not have them.    8)  Install vibration dampening material on the tool rests of the stand grinders.    9)  Install vibration dampening material on the part stands for the swing grinders.    10)  Install noise dampening material on the swing grinder enclosure surfaces.          ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Sep 4, 2012

Penalty

Initial $5,000 · Current $5,000

General-duty citation text

29 CFR 1910.146(c)(7)(iii): The employer did not document the basis for determining that all hazards in a permit space had been eliminated, through a written certification that contained the date, the location of the space, and the signature of the person making the determination:    a) Employees entering identified permit required confined spaces with all the hazards eliminated using lockout procedures were not documenting the basis for determining that all the hazards had eliminated.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Sep 4, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3): Under the permit-required confined space program required by 29 CFR 1910.146(c)(4), the employer did not develop and implement the means, procedures, and practices necessary for safe permit space entry operations:    a)  Employees were not complying with the company's written Confined Space Non-Permit - Permit Required Instruction. Employees were utilizing alternative procedures described in 29 CFR 1910.146(c)(7) for entry into all identified permit required confined spaces. The company's written Confined Space Non-Permit - Permit Required Instruction does not include reclassification procedures nor have the identified permit required confined spaces been evaluated to determine if the potential hazards and configuration of the confined spaces meet the inclusion requirements of 29 CFR 1910.146(c)(7).         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jun 2, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:    a) On 11/08/11, the employer had not documented energy control procedures for isolating the potential hazardous energy sources in the BMD Mold Separation area for a BMD Operator/Mechanic troubleshooting and repairing the BMD North Separator Clamp.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jun 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Authorized employee(s) did not receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control:    a) The employer did not provide training to the BMD Operator/Mechanic concerning the hazard the BMD Group III Transfer Clamps presented while troubleshooting and repairing the BMD North Separator Clamp.    b) The employer did not provide training to the BMD Operator/Mechanic concerning the means and methods to be utilized for energy isolation of the BMD Mold Separation Area while troubleshooting and repairing the BMD North Separator Clamp.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Aug 1, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(f)(1): When lockout or tagout devices temporarily were removed from the energy isolating device and the machine or equipment was energized to test or position the machine, equipment or component thereof, the sequence of actions in 29 CFR 1910.147(f)(1)(i) through (v) were not followed:    (a)  The company had not implemented procedures to provide employee protection while testing or positioning energized machines, equipment or components after energy controls are temporarily removed. On 11/08/11, a BMD Operator/Mechanic entered the BMD Mold Separation Area when the BMD Group II Separation Clamps were in Manual Operation and the Group III Transfer Arms were in Automatic Operation.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jun 2, 2012

Penalty

Initial $5,000 · Current $5,000

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct an annual or more frequent inspection of the energy control procedure to ensure that the procedure and requirements of this standard were followed:     a) The employer had not conducted periodic inspections of the energy control procedures in the past year.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jun 2, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s):    a) On 11/08/11, the BMD Group III Transfer Arms were not de-energized while an employee was working on the BMD Group II Mold Separation Clamps. The BMD Group III Transfer Arms move above the BMD Group II Mold Separation Clamps.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $5,000 · Current $5,000

General-duty citation text

29 CFR 1910.178(l)(4)(iii): An evaluation of each powered industrial truck operator's performance was not being conducted at least once every three years:    a)  The employer had not re-evaluated powered industrial truck operator's performance since 2007.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Aug 1, 2012

Penalty

Initial $5,000 · Current $5,000

General-duty citation text

29 CFR 1910.179(j)(3): A complete periodic inspection of crane(s) had not been conducted in the past 12 months:    a) The Plant #1 P & H 5 Ton Yard Crane had not received a complete periodic inspection in the last past 12 months.    b) The Plant #2 P & H 10 Ton Yard Crane had not received a complete periodic inspection in the past 12 months.    c) The Plant #2 Melt Deck gantry crane had not received a complete periodic inspection in the past 12 months.    d) The Plant #2 BMD Shakeout Area gantry crane had not received a complete periodic inspection in the past 12 months.    e) The Plant #1 Disa Shakeout Area gantry crane had not received a complete periodic inspection in the past 12 months.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Penalty

Initial $4,250 · Current $4,250

General-duty citation text

29 CFR 1910.212(a)(1): Machine guarding was not provided to protect operator(s) and other employees from hazard(s) created by rotating parts and crush points:    a) On 11/22/11, the Summit 250 M Horizontal Bandsaw #006-048 did not have the unused portion of the blade guarded located in the Maintenance Area of Plant #4.    b) On 12/13/11, the point where the cope and the drag are joined was accessable to the Mold Blower Operator in the Mold Blower Operator Station.    c)  On 11/22/11, the rotating shafts of the gang drill dies were accessable through the missing guard sections in the Plant #3 Machining Center.         NO ABATEMENT DOCUMENTATION OR ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Penalty

Initial $2,550 · Current $2,550

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:    a) On 11/21/11, the Hot Shot 400 FS-FD electrical cover hinge was damaged and the cover was not kept closed. The Hot Shot 400 FS-FD was located in Plant #1, near the Core Storage Area.    b) On 11/22/11, a slot in breaker box BP-M3 was open allowing access to the buss bar. Breaker box BP-M3 is located in the Plant #4 Maintenace Area.         NO ABATEMENT DOCUMENTATION OR ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Aug 1, 2012

Penalty

Initial $4,000 · Current $4,000

General-duty citation text

29 CFR 1910.1025(c)(1): Employee(s) were exposed to lead at concentrations greater than fifty micrograms per cubic meter (ug/m3) of air averaged over an eight-hour period:    a) On 12/07/11, a Plant #1 Furnace Operator was monitored for 425 minutes and exposed to an airborne lead level of 59 ug/m3 as an 8 hour time-weighted average which is 1.19 times the permissible exposure limit.    b) On 01/04/12, a Plant #2 Herman Iron Pourer was monitored for 487 minutes and exposed to an airborne lead level of 50.5 ug/m3 as an 8 hour time-weighted average which is 1.01 times the permissible exposure limit.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1025(e)(1)(i): For any employees exposed to lead above the permissible exposure limit for more than 30 days per year the employer did not implement engineering and work practice controls (including administrative controls) were not implemented to reduce and maintain employee exposure to lead :    a) The employer did not maintain engineering controls and/or work practice controls to the Plant #1 Furnace Operator and the Plant #2 Herman Iron Pourer below the permissible exposure limit of 50 ug/m3.    Applicable engineering and work practice controls to reduce exposures may include, but are not limited, to the following:  1) Repair any furnace covers in Plant #1 and 2 that are not seating correcting.  2) Check the raw iron materials for lead content and remove contaminated sources.  3) Check the copper and other alloy metals for tramp lead and remove contaminated sources.           ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1025(e)(2): Respiratory protection was not provided to supplement engineering and work practice controls, that did not control employees exposure to or below 50 micrograms per cubic meter:    b)  The Plant #2 Herman Iron Pourer, who was over exposed to lead, was not required to wear respirator protection while working near molten iron.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1025(e)(3)(i): The employer did not establish and implement a written compliance program to reduce exposures to or below the permissible exposure limit, solely by means of engineering and work practice controls:    a)  The company had not established or implemented a written compliance program to reduce the employees' lead exposure to or below the permissible exposure limit.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1025(i)(4)(iv): Employees entering lunchroom facilities with protective work clothing or equipment were not required to remove surface lead dust by vacuuming, downdraft booth, or other cleaning method(s):    a) Employees over exposed to lead did not ensure surface lead dust had been removed from their work clothing before entering the lunchrooms.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1025(j)(1)(i): A medical surveillance program was not instituted for all employee(s) who were, or could be exposed to lead above the action level for more that thirty days per year:    a) The employer had not established a medical surveillance program for the employees over exposed to lead.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $4,000 · Current $4,000

General-duty citation text

29 CFR 1910.1025(l)(1)(i): Employee(s) working in an area where there is potential exposure to airborne lead at any level were not informed of the content of Appendices A and B of 29 CFR 1910.1025:    a) The employer did not inform employees potentially exposed to lead about the contents of Appendices A and B of 29 CFR 1910.1025.         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1025(l)(1)(ii): The employer did not train each employee who is subject to exposure to lead at or above the action level, or for whom the possibility of skin or eye irritation exists, in accordance with the requirements of 29 CFR 1910.1025:    a) The employer did not provide employees over exposed to lead the information required by 29 CFR 1910.1025(l)(1)(v)(A through G).         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $3,000 · Current $3,000

General-duty citation text

29 CFR 1910.1048(m)(5): The employer did not develop, implement, and maintain at the workplace, a written hazard communication program for formaldehyde exposures in the workplace, which at a minimum described how the requirements specified in this paragraph for labels and other forms of warning and material safety data sheets, and paragraph (n) for employee information and training, would be met:    a) The employer had not developed a written hazard communication program for formaldehyde when air monitoring in 2008 indicated employees were exposed to airborne levels of formaldehyde over 0.1 ppm.          ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1048(n)(1): The employer did not ensure that all employees who were assigned to workplaces where there was exposure to formaldehyde participated in a training program:    a) The employer did not train employees with exposure to formaldehyde on the information required by 29 CFR 1910.1048(n)(3)(i) through (vii).         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.

Issued

May 3, 2012

Abate by

Jul 2, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1028(j)(3)(i): The employer did not provide employees with information and training at the time of their initial assignment to a work area where benzene was present:    a) The employer did not train the employees with exposure to benzene on the information required by 29 CFR 1910.1028(j)(2) and (j)(3).         ABATEMENT DOCUMENTATION AND ABATEMENT CERTIFICATION REQUIRED.