OSHA Inspection: B.W. GRINDING CO.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): 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 struck-by  and crushing hazards.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about June 27, 2012, employees working in the green sand molding department were exposed to struck-by and crushing hazards when using a skip hoist with a damaged hoist rope.  The hoist rope had approximately half of the strands broken and was still being used to lift the skip hoist bucket containing approximately 800 pounds of sand.      Among other methods, one feasible and acceptable method to correct the hazard is to ensure that the wire rope is maintained according to ASME B20.1 2009 "Safety Standard for Conveyors and Related Equipment" Section 6.14.3 by requiring the hoist rope being removed from service when the wear indicates a possibility of failure and Wire Rope Users Manual, Second Edition, published by the American Iron and Steel Institute.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.23(c)(1): Every open-sided floor or platform 4 feet or more above adjacent floor or ground level was not guarded by a standard railing (or the equivalent as specified in paragraph (e)(3) of this section) on all open sides except where there is entrance to a ramp, stairway, or fixed ladder:    a.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the platform located in the molding area, used by employees to check catalyst and resin levels in the chemical tanks, was equipped with a standard guardrail exposing employees to a 53 inch fall to concrete.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $4,900 · Current $2,450 Reduced

Hazardous substances 8110

General-duty citation text

29 CFR 1910.95(c)(1): The employer did not administer a continuing, effective hearing conservation program, as described in paragraphs (c) through (o) of this section, whenever employee noise exposures equal or exceeded an 8-hour time-weighted average sound level (TWA) of 85 decibels measured on the A scale (slow response) or, equivalently, a dose of fifty percent. For purposes of the hearing conservation program, employee noise exposures shall be computed in accordance with appendix A and Table G-16a, and without regard to any attenuation provided by the use of personal protective equipment.    a.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about June 27, 2012, the employer did not ensure an effective hearing conservation program consisting of hearing conservation training and audiometric testing was implemented in the green sand molding department were employees were performing molding operations.  Employees received a noise dose of 116% at an equivalent dBA of 91.1 during a sampling time 470 minutes.      b.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about June 27, 2012, the employer did not ensure an effective hearing conservation program consisting of hearing conservation training and audiometric testing was implemented in the sand reclaim department where employees were performing the sand reclaim operation.  Employees received a noise dose of 122% at an equivalent dBA of 91.4 during a sampling time 470 minutes.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.106(e)(2)(ii)(b)(2): The quantity of liquid that may be located outside of an inside storage room or storage cabinet in a building or in any one fire area of a building exceeded 120 gallons of Catagory 2, 3, or 4 flammable liquids in containers.    a.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure no more than 120 gallons of Catagory 2 flammable liquids were stored in a single fire area.  Two-55 gallon drums of Refcahol, one-55 gallon drum of Refcosolv and four-5 gallon buckets of Refcosolv were located outside of the supervisors office adjacent to the melt department.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.133(a)(3): The employer did not ensure that each affected employee who wore prescription lenses while engaged in operations that involve eye hazards wears eye protection that incorporates the prescription in its design, or wore eye protection that could be worn over the prescription lenses without disturbing the proper position of the prescription lenses or the protective lenses.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about August 23, 2012, the employer did not ensure an employee working in the finishing department grinding castings and performing various small jobs was wearing safety glasses.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.134(c)(1): In any workplace where respirators were necessary to protect the health of the employee or whenever respirators were required by the employer, the employer did not establish and implement a written respiratory protection program with worksite-specific procedures. The program shall be updated as necessary to reflect those changes in workplace conditions that affect respirator use. The employer shall include in the program the following provisions of this section, as applicable:    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the written respiratory protection program contained the following information:    1. Provisions for medical evaluations;  2. Description of the fit testing procedures;  3. Procedures for proper cleaning, cleaning schedules, disinfecting, storing, inspecting, repairing, and maintaining respirators;

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(h)(2)(i): All respirators were not stored to protect them from damage, contamination, dust, sunlight, extreme temperatures, excessive moisture, and damaging chemicals, and they shall be packed or stored to prevent deformation of the facepiece and exhalation valve.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, The employer did not ensure respirators were stored to protect them from contamination.  The inside of the respirator storage cabinet located next to the shipping office was covered in dust and not kept clean.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(k)(1)(v): The employer did not ensure  that each employee could demonstrate knowledge of what the procedures were for maintenance and storage of the respirator.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 25, 2012, the employer did not ensure employees were provided with training on how to properly maintain and store the respirators.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(l)(1): The employer did not conduct evaluations of the workplace as necessary to ensure that the provisions of the current written program are being effectively implemented and that it continues to be effective.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the company's respiratory protection program was being properly implemented.  The company failed to ensure initial medical evaluations were being performed, employees were not properly trained on respirator maintenance and storage, the company's written respirator program was deficient.

Issued

Nov 6, 2012

Abate by

Dec 10, 2012

Penalty

Initial $4,900 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer did not identify and evaluate the respiratory hazard(s) in the workplace; this evaluation did not include a reasonable estimate of employee exposures to respiratory hazard(s) and an identification of the contaminant's chemical state and physical form:    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure an evaluation was performed to determine employee exposures to respirable crystalline silica dust in the grinding operation and the table blast operation.

Issued

Nov 6, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding were not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks.     a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure employees working in the green sand department were protected from nip point and crushing hazards created by the movement of the skip hoist bucket.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.243(c)(2)(i): Cup wheels were not protected by safety guards as specified in paragraph (c)(1) of this section.    a.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure hand held cup wheel grinders used by employees working in the finishing department were properly guarded.

Issued

Nov 6, 2012

Abate by

Nov 26, 2012

Penalty

Initial $4,900 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.332(b)(1): Employees were not trained in and familiar with the safety-related work practices required by 1910.331 through 1910.335 that pertain to their respective job assignments.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about July 23, 2012, the employer did not ensure a maintenance employee was properly trained on what electrical protective equipment was required to be worn while troubleshooting fuses in a 480 volt electrical cabinet for the palmer sand mixer.

Issued

Nov 6, 2012

Abate by

Nov 27, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there are potential electrical hazards were not provided with, and required to use, electrical protective equipment that was appropriate for the specific parts of the body to be protected and for the work to be performed.     a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about July 23, 2012, the employer did not ensure a maintenance employee was wearing electrical protective equipment for the body and hands while troubleshooting fuses in a 480 volt electrical cabinet for the palmer sand mixer.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(v): Employees did not wear protective equipment for the eyes or face wherever there was danger of injury to the eyes or face from electric arcs or flashes or from flying objects resulting from electrical explosion.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about July 23, 2012, the employer did not ensure a maintenance employee was wearing electrical protective equipment for the face while troubleshooting fuses in a 480 volt electrical cabinet for the palmer sand mixer.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.137(b)(2)(viii): Electrical protective equipment was not subjected to periodic electrical tests. Test voltages and the maximum intervals between tests shall be in accordance with Table I-5 and Table I-6.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about July 23, 2012, the employer did not ensure the electrical insulated rubber gloves available for maintenance employees to wear when exposed to electrical hazards, were tested every six months.

Issued

Nov 6, 2012

Abate by

Jun 15, 2013

Penalty

Initial $4,900 · Current $2,450 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1000(c): An employee's exposure to any substance listed in Table Z-3, in any 8-hour work shift of a 40-hour work week, exceeded the 8-hour time weighted average limit given for that substance in the table.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about June 27, 2012, an employee operating the table blast machine adjacent to the finishing department was overexposed to respirable crystalline silica dust at 1.28 mg/m3 as an 8-hour time weighted average which was 1.3 times the OSHA PEL of 0.97 mg/m3. The sampling period was 462 minutes with zero exposure used for the unsampled portion of the work shift.

Issued

Nov 6, 2012

Abate by

Jun 15, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1000(e): To achieve compliance with paragraphs (a) through (d) of this section, administrative or engineering controls were not determined and implemented whenever feasible. When such controls were not feasible to achieve full compliance, protective equipment or any other protective measures were not used to keep the exposure of employees to air contaminants within the limits prescribed in this section.     a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about June 27, 2012, the employer did not determine and implement feasible engineering controls to control employee exposure to respirable crystalline silica.  An employee operating the table blast machine adjacent to the finishing department was overexposed to respirable crystalline silica dust at 1.28 mg/m3 as an 8-hour time weighted average which was 1.3 times the OSHA PEL of 0.97 mg/m3. The sampling period was 462 minutes with zero exposure used for the unsampled portion of the work shift.    Step 1: Provide effective respiratory protection and ensure it is used by 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.    Step 2: A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced 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;  (4)	Testing and acceptance or modification/redesign.    All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.  90 day progress reports are required during the abatement period.    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.    Feasible engineering controls include, but are not limited to installing more efficient duct work leading from the table blast to the bag house and ensuring the baghouse filters are replaced as needed to ensure the maximum performance of the ventilation equipment.       	Step1: Abatement Date-    	Step2: Abatement Date-    	Step3: Abatement Date-

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $4,900 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.1200(h)(3)(ii): Employee training did not include the physical and health hazards of the chemicals in the work area:      a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer failed to ensure employees working in the green sand molding department were trained on the physical and health effects of coal tar pitch volatiles which are emitted during the metal pouring operation.      b. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer failed to ensure employees working in the finishing department, table blast, molding department, and sand reclamation area were trained on the health effects of silica dust.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(h)(3)(iv): Employee training did not include the details of the hazard communication program developed by the employer, including an explanation of the labeling system and the material safety data sheet, and how employees can obtain and use the appropriate hazard information:    c. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure amployees in all departments were provided with an explanation of the material safety data sheets.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.1200(f)(5)(i): The employer did not ensure each container of hazardous chemicals in the workplace was labeled, tagged, or marked with the identity of the hazardous chemical(s) contained therein.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the resin tank containing approximately 100 gallons of furfuryl alcohol and formaldehyde located next to the palmer sand mixer in the molding area, was labeled as to the identity of the substance.    b. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the catalyst tank containing approximately 250 gallons of toluene sulfonic acid catalyst located adjacent to the Kloster sand mixer in the no-bake department, was labeled as to the identity of the substance.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(f)(5)(ii):  The employer did not ensure each container of hazardous chemicals in the workplace was labeled, tagged, or marked with the appropriate hazard warnings, or alternatively, words, pictures, symbols, or combination thereof, which provide at least general information regarding the hazards of the chemicals, and which, in conjunction with the other information immediately available to employees under the hazard communication program, will provide employees with the specific information regarding the physical and health hazards of the hazardous chemical.    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the resin tank containing approximately 100 gallons of furfuryl alcohol and formaldehyde located next to the palmer sand mixer in the molding area, was labeled as to the physical and health hazards of the substance.    b. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure the catalyst tank containing approximately 250 gallons of toluene sulfonic acid catalyst located adjacent to the Kloster sand mixer in the no-bake department, was labeled as to the physical and health hazards of the substance.

Issued

Nov 6, 2012

Abate by

Nov 26, 2012

Penalty

Initial $49,000 · Current $24,500 Reduced

Hazardous substances 8110

General-duty citation text

29 CFR 1910.95(c)(1): The employer did not administer a continuing, effective hearing conservation program, as described in paragraphs (c) through (o) of this section, whenever employee noise exposures equal or exceeded an 8-hour time-weighted average sound level (TWA) of 85 decibels measured on the A scale (slow response) or, equivalently, a dose of fifty percent. For purposes of the hearing conservation program, employee noise exposures shall be computed in accordance with appendix A and Table G-16a, and without regard to any attenuation provided by the use of personal protective equipment.      a.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about June 27, 2012, the employer did not ensure an effective hearing conservation program was implemented in the finishing department for employees performing the grinding operation which consisted of hearing conservation training and audiometric testing.  Employees received a noise dose of 312% at an equivalent dBA of 98.2 during a sampling time 464 minutes.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $28,000 · Current $14,000 Reduced

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace. The employer may discontinue an employee's medical evaluations when the employee is no longer required to use a respirator.    a.  B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure employees wearing powered air purifying respirators (PAPR) while grinding in the finishing department, were provided with medical evaluations prior to being required to wear the respirators.

Issued

Nov 6, 2012

Abate by

Nov 16, 2012

Penalty

Initial $700 · Current $350 Reduced

General-duty citation text

29 CFR 1904.4(a): The employer did not record each work-related fatality, injury, or illness case that resulted in the general recording criteria on the OSHA 300 or equivalent:      a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 7, 2012, and May 11, 2012, the employer did not record the following work place injuries or illnesses on the OSHA 300 or equivilant.     -An employee received a molten metal burn on his buttock while charging the furnce and subsequently received antibiotics,      prescription narcotics.     -An employee suffered an eye injury when metal particles entered his eye and neede to be removed by a doctor.  The employee received prescription medications and was placed on restricted duty.

Issued

Nov 6, 2012

Abate by

Nov 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(D): Lockout devices and tagout devices did not indicate the identity of the employee applying the device(s).    a. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about May 24, 2012, the employer did not ensure an employee working inside of the table blast machine removing castings, placed a lockout device on the electrical disconnect which identified the employee performing the lockout.    b. B.W. Grinding Co. dba B.W. Supply located in Lyons, Ohio:  On or about August 23, 2012, the employer did not ensure an employee cleaning the sand mixer located in the loop molding area, placed a lockout device on the electrical disconnect which identified the employee performing the lockout.