OSHA Inspection: NEW JERSEY SHELL CASTING CORPORATION

Issued

May 2, 2013

Abate by

Jun 6, 2013

Penalty

Initial $2,040 · Current $1,220 Reduced

Hazardous substances 159190109130

General-duty citation text

29 CFR 1910.134(c)(1): A written respiratory protection program that included the provisions in 29 CFR 1910.134(c)(1)(i) - (ix) with worksite specific procedures was not established and implemented for required respirator use:    a) In the Molding and Grinding Areas - On or about November 7, 2012, the employer had not implemented the written respiratory protection program to protect employees exposed to airborne lead above action level of 30 micrograms per cubic meter of air (30 µg/m(3)) averaged over an 8-hour period and wearing the full-face powered air purifying respirators, and the 3M 6291 tight-fitting elastomeric half-face with P100 filter cartridges.      Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

May 29, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 159190109130

General-duty citation text

29 CFR 1910.134(h)(1): Respirators were not cleaned and disinfected using the procedures in Appendix B-2 of 29 CFR 1910.134 or equivalent procedures recommended by the respirator manufacturer:  a) In the Furnace, Molding, and Grinding Areas - On or about November 15, 2012, the employer had not ensured that the full-face powered air purifying respirators, and tight-fitting elastomeric half-face with HEPA filter cartridges used by employees, exposed to airborne lead above the action level of 30 micrograms per cubic meter of air (30 µg/m(3)) averaged over an 8-hour period, were cleaned and disinfected using the procedures in Appendix B-2 of this section.     Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

Jun 6, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 0730159190109130

General-duty citation text

29 CFR 1910.134(k)(5): Respiratory protection retraining was not conducted annually:  a) In the Furnace, Molding, and Grinding Areas - On or about November 7, 2012, the employer had not provided employees,  exposed to airborne lead above the action level concentration of 30 micrograms per cubic meter (µg/m(3)), comprehensive and understandable information and training on proper respirator fit, use, storage, inspection, maintenance, cleaning, and the limitations, capabilities, and possible malfunctions of the full-face powered air purifying respirators, and tight-fitting elastomeric half-face with HEPA filter cartridges provided for the employees in the production areas.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

May 29, 2013

Penalty

Initial $2,040 · Current $1,220 Reduced

Hazardous substances 0730159190109130

General-duty citation text

29 CFR 1910.141(g)(2): Employees were permitted to consume food or beverage in area(s) exposed to toxic materials:    a) In the Employee Lunch Room - On or about November 21, 2012, the employer, producing metal castings, had allowed employees to consume food and beverages in the Employee Lunch Room, an area exposed to lead and copper residues, toxic materials.     Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

May 29, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 0730159190109130

General-duty citation text

29 CFR 1910.1025(h)(1): All surfaces were not maintained as free as practicable of accumulations of lead:  a) In the Employee Lunch Room - On or about November 21, 2012, the employer had allowed lead residue to accumulate on the northwest corner of the northern most table.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

Jun 6, 2013

Penalty

Initial $2,040 · Current $1,220 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(d)(6)(iii): Where the initial monitoring revealed that employee exposure to lead was above the permissible exposure limit, ; monitoring was not repeated at least quarterly and continued at the required frequency until at least two consecutive measurements taken at least 7 days apart were below the PEL and at or above the action level:    a) In the Furnace and Molding Areas - On or about November 7, 2012, the employer did not repeat monitoring at the frequency specified in this paragraph, quarterly for employees exposed above the permissible exposure limit and every six months for employees exposed at or above the action level of 30 micrograms per cubic meter of air (30 µg/m(3)) averaged over an 8-hour period until two consecutive measurements, at least 7 days apart show exposures below the action level, after monitoring done on or about February 1, 2010, showed the Pourer and the Furnace Man exposed to airborne lead over the permissible exposure limit of 50 µg/m(3).    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

Jun 13, 2013

Penalty

Initial $2,040 · Current $1,220 Reduced

Hazardous substances 1591

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) In the Molding and Grinding Areas - On or about November 7, 2012, the employer had not instituted a medical surveillance program for employees, working in the cast metal production areas, who were exposed to lead above the action level [30 micrograms per cubic meter of air (30 µg/m(3)) averaged over an 8-hour period] for more than 30 days per year.     Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

Jun 6, 2013

Penalty

Initial $1,700 · Current $1,020 Reduced

Hazardous substances 1591

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) In the Furnace, Molding, and Grinding Areas - On or about November 7, 2012, the employer had not ensured that employees, working in the cast metal production areas, could demonstrate knowledge of the content of Appendices A and B of this regulation.     Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

Jun 6, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 1591

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) In the Molding and Grinding Areas - On or about November 7, 2012, the employer, producing cast metal, had not ensured that employees, exposed to airborne lead concentrations above the action level [30 micrograms per cubic meter of air (30 µg/m(3)) averaged over an 8-hour period], were informed of the information outlined in 29 CFR 1910.1025(l)(1)(v)(A)-(G), meaning A. contents of 29 CFR 1910.1025 and its appendices; B. operations that could result in lead exposure above the action level; C. purpose, fitting, use, selection, and limitations of respirators; D. the purpose and a description of the medical surveillance program and medical removal program with an emphasis on the health and reproductive health effects of lead exposure; E. engineering and work practice exposure controls associated with the employees job assignment; F. the contents of any compliance plan in effect; and G. Instructions that chelating agents should not be used at all except under the direction of a licensed physician.    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 2, 2013

Abate by

Jun 6, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:  a) At the Establishment - On or about November 7, 2012, the employer had not provided employees with effective information and training on the physical and health hazards associated with methylene bisphenyl isocyanate (MDI), respirable silica, lead fumes, and copper fumes.    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.