WAUKESHA, WI —
OSHA Inspection: CASTALLOY, INC.
Follow-up inspection · Health discipline
At a glance
On , OSHA opened a follow-up health inspection of CASTALLOY, INC. in 1701 INDUSTRIAL LANE, WAUKESHA, WI 53189 (NAICS 331513). OSHA activity number 337589618.
What this inspection record means
OSHA opens inspections for many reasons — routine scheduling under a national or local emphasis program, an employee complaint or referral, or a follow-up after a reported injury. Opening or conducting an inspection is not itself an allegation or a finding that this employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.
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Where did this inspection happen?
- Establishment
- CASTALLOY, INC.
- Site address
- 1701 INDUSTRIAL LANE
- City
- WAUKESHA
- State
- WI
- ZIP
- 53189
- Mailing
- P.O. BOX 827, WAUKESHA, WI 53187
What kind of inspection was it?
- Inspection type
- Follow-up (F)
- Scope
- Partial (B)
- Discipline
- Health
- Advance notice
- No
- Union status
- B
When did the case open and close?
- Opened
- Closing conference
- Case closed
- Last modified
- Data loaded
Establishment context
- NAICS code
- 331513
- Employees
- 132
- Ownership type
- A
Citations
15 citations on file for this inspection.
1910.134 D01 I
- Issued
- May 15, 2013
- Abate by
- Jun 11, 2013
- Penalty
- Initial $6,930 · Current $4,851 Reduced
0700
General-duty citation text
29 CFR 1910.134(d)(1)(i): Selection of appropriate respirators was not based on the respiratory hazard(s) to which the worker was exposed and user factors that affect respirator performance and reliability: (a) The two shake out employees and the two deck hands were exposed to coal tar pitch variables in excess of the permissible exposure limit and were not assigned proper respiratory protection. (b) The two deck hands were exposed to coal tar pitch volatiles over the permissible exposure limit and less than 10 times the permissible exposure limit and were not assigned respiratory protection that was a minimum of half mask air purifying respirator.
Recent events (3)
- — F (S) $4851
- — C (S) $6930
- — Z (S) $6930
1910.134 E07 IV
- Issued
- May 15, 2013
- Abate by
- Jun 11, 2013
- Penalty
- Initial $6,930 · Current $0 Reduced
1290
General-duty citation text
29 CFR 1910.134(e)(7)(iv): The employer did not provide additional medical evaluations that complied with the requirements of 29 CFR 1910.134 when a change occurred in the workplace conditions that resulted in a substantial increase in the physiological burden placed on an employee: (a) The molders on molding line 2 were medically evaluated for the purpose of wearing disposable N95 filtering facepieces (dust masks) and were assigned air purifying respirators fitted with combination chemical cartridges and HEPA filters (P100) and were not re-evaluated.
Recent events (3)
- — F (O) $0
- — C (S) $6930
- — Z (S) $6930
1910.1048 G02 II A
- Issued
- May 15, 2013
- Abate by
- May 21, 2013
- Penalty
- Initial $6,930 · Current $4,851 Reduced
1290
General-duty citation text
29 CFR 1910.1048(g)(2)(ii)(A): When air-purifying chemical-cartridge respirators were used, the employer did not replace the cartridge after three hours of use or at the end of the workshift, whichever occurs first: (a) The molder on molding line 2 was exposed to formaldehyde at an 8-hour time weighted average of 1.30 parts per million, approximately 1.7 times the limit of 0.75 parts per million did not change his respirator cartridge after three hours of use and instead changed his respirator cartridge every two to three weeks.
Recent events (3)
- — F (S) $4851
- — C (S) $6930
- — Z (S) $6930
1910.134 G01 I A
- Issued
- May 15, 2013
- Abate by
- May 21, 2013
- Penalty
- Initial $6,930 · Current $0 Reduced
General-duty citation text
29 CFR 1910.134(g)(1)(i)(A): Respirators with tight-fitting facepieces were worn by employees who had facial hair that came between the sealing surface of the facepiece and the face or that interfered with valve function: (a) The molder, required to wear the negative pressure, half-facepiece respirator, had a multi-day growth of beard that came between the sealing surface of the respirator facepiece and the employee's face.
Recent events (3)
- — F (S) $0
- — C (S) $6930
- — Z (S) $6930
1910.134 G02 II C
- Issued
- May 15, 2013
- Abate by
- May 21, 2013
- Penalty
- Initial $6,930 · Current $0 Reduced
1290
General-duty citation text
29 CFR 1910.134(g)(2)(ii)(C): The employer did not ensure that employees left the respirator use area when they were replacing the respirator or the filter, cartridge, or canister elements: (a) During air sampling on February 12, 2013 employees in the molding area at molding line 2 replaced their respirator cartridges, used for protection from formaldehyde, while standing at their work stations.
Recent events (3)
- — F (S) $0
- — C (S) $6930
- — Z (S) $6930
1910.1048 C01
- Issued
- May 15, 2013
- Abate by
- Jun 11, 2013
- Penalty
- Initial $6,930 · Current $0 Reduced
1290
General-duty citation text
29 CFR 1910.1048(c)(1): Employees were exposed to an airborne concentration of formaldehyde which exceeded 0.75 parts per million, as an 8-hour time weighted average: (a) The molder on molding line 2 was exposed to formaldehyde at an 8-hour time weighted average of 1.30 parts per million, approximately 1.7 times the limit of 0.75 parts per million. This limit is established to prevent respiratory cancers, genotoxicity, and respiratory impairment. The sample was collected on December 12, 2012 during a 471 minute sampling period; exposure calculations include a zero increment for the 9 minutes not sampled.
Recent events (3)
- — F (S) $0
- — C (S) $6930
- — Z (S) $6930
1910.1048 F01
- Issued
- May 15, 2013
- Abate by
- Feb 7, 2014
- Penalty
- Initial $0 · Current $0
1290
General-duty citation text
29 CFR 1910.1048(f)(1): Engineering controls and work practices were not instituted to reduce and maintain employee exposures to formaldehyde at or below the TWA and the STEL: (a) The molder on molding line 2 was exposed to formaldehyde at an 8-hour time weighted average of 1.30 parts per million, approximately 1.7 times the limit of 0.75 parts per million. This limit is established to prevent respiratory cancers, genotoxicity, and respiratory impairment. The sample was collected on December 12, 2012 during a 471 minute sampling period; exposure calculations include a zero increment for the 9 minutes not sampled.
Recent events (3)
- — F (S) $0
- — C (S) $0
- — Z (S) $0
1910.1048 E01 I
- Issued
- May 15, 2013
- Abate by
- Jun 11, 2013
- Penalty
- Initial $6,930 · Current $1,000 Reduced
1290
General-duty citation text
29 CFR 1910.1048(e)(1)(i): The employer did not establish regulated areas where the concentration of airborne formaldehyde exceeded either the TWA or the STEL and post all entrances and access ways with signs bearing the following legend: DANGER FORMALDEHYDE MAY CAUSE CANCER CAUSES SKIN, EYE, AND RESPIRATORY IRRITATION AUTHORIZED PERSONNEL ONLY (a) The molder on molding line 2 was exposed to formaldehyde at an 8-hour time weighted average of 1.30 parts per million, approximately 1.7 times the limit of 0.75 parts per million and there was no regulated area established nor were signs posted.
Recent events (3)
- — F (O) $1000
- — C (S) $6930
- — Z (S) $6930
1910.1048 G03 II
- Issued
- May 15, 2013
- Abate by
- May 21, 2013
- Penalty
- Initial $6,930 · Current $0 Reduced
1290
General-duty citation text
29 CFR 1910.1048(g)(3)(ii): The employer substituted an air-purifying, half mask respirator for an air-purifying, full facepiece respirator equipped with a cartridge approved for protection against formaldehyde and did not provide the affected employees with effective gas-proof goggles: (a) The molder on molding line 2 was exposed to formaldehyde at an 8-hour time weighted average of 1.30 parts per million, approximately 1.7 times the limit of 0.75 parts per million and wore standard safety glasses.
Recent events (3)
- — F (S) $0
- — C (S) $6930
- — Z (S) $6930
1910.1000 A02
- Issued
- May 15, 2013
- Abate by
- Jun 11, 2013
- Penalty
- Initial $13,860 · Current $0 Reduced
0700
General-duty citation text
29 CFR 1910.1000(a)(2): An employee(s) exposure to any substance in Table Z-1, the exposure limit of which is not preceded by a "C", exceeded the 8-hour Time Weighted Average given for that substance in any 8-hour work shift of a 40-hour work week: (a) The shake out employee in the shake out area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 6.3 mg/m3, approximately 32 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 472 minute sampling period; exposure calculations include a zero increment for the 8 minutes not sampled. (b) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 3.3 mg/m3, approximately 17 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 472 minute sampling period; exposure calculations include a zero increment for the 8 minutes not sampled. (c) The shake out employee in the shake out area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 2.3 mg/m3, approximately 12 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 459 minute sampling period; exposure calculations include a zero increment for the 21 minutes not sampled. (d) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 2.0 mg/m3, approximately 10 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 460 minute sampling period; exposure calculations include a zero increment for the 20 minutes not sampled. (e) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 1.9 mg/m3, approximately 10 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 455 minute sampling period; exposure calculations include a zero increment for the 25 minutes not sampled. (f) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 1.8 mg/m3, approximately 9 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 463 minute sampling period; exposure calculations include a zero increment for the 17 minutes not sampled. Castalloy, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.1000(a)(2), which was contained in OSHA inspection number 315119255, citation number 1, item number 3b, and was affirmed as a final order on July 12, 2012, with respect to a workplace located at 1701 Industrial Lane, Waukesha, WI 53189.
Recent events (3)
- — F (R) $0
- — C (R) $13860
- — Z (R) $13860
1910.1000 E
- Issued
- May 15, 2013
- Abate by
- Feb 7, 2014
- Penalty
- Initial $0 · Current $0
0700
General-duty citation text
29 CFR 1910.1000(e): Feasible administrative or engineering controls were not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d): (a) The shake out employee in the shake out area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 6.3 mg/m3, approximately 32 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 472 minute sampling period; exposure calculations include a zero increment for the 8 minutes not sampled. (b) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 3.3 mg/m3, approximately 17 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 472 minute sampling period; exposure calculations include a zero increment for the 8 minutes not sampled. (c) The shake out employee in the shake out area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 2.3 mg/m3, approximately 12 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 459 minute sampling period; exposure calculations include a zero increment for the 21 minutes not sampled. (d) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 2.0 mg/m3, approximately 10 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 460 minute sampling period; exposure calculations include a zero increment for the 20 minutes not sampled. (e) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 1.9 mg/m3, approximately 10 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 455 minute sampling period; exposure calculations include a zero increment for the 25 minutes not sampled. (f) The deck hand employee in the pouring deck area was exposed to coal tar pitch volatiles at an 8-hour time weighted average of 1.8 mg/m3, approximately 9 times the limit of 0.2 mg/m3. This limit is established to prevent cancer of the lung, kidney and skin. The sample was collected on December 18, 2012 during a 463 minute sampling period; exposure calculations include a zero increment for the 17 minutes not sampled. Feasible means of abatement include increasing general ventilation on the pouring deck. Castalloy, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.1000(a)(2), which was contained in OSHA inspection number 315119255, citation number 1, item number 3c, and was affirmed as a final order on July 12, 2012, with respect to a workplace located at 1701 Industrial Lane, Waukesha, WI 53189.
Recent events (3)
- — F (R) $0
- — C (R) $0
- — Z (R) $0
1910.1048 L01 I
- Issued
- May 15, 2013
- Abate by
- Jun 11, 2013
- Penalty
- Initial $13,860 · Current $0 Reduced
1290
General-duty citation text
29 CFR 1910.1048(l)(1)(i): The employer did not institute medical surveillance programs for all employees exposed to formaldehyde at concentrations at or exceeding the action level or exceeding the STEL: (a) There was no medical surveillance program implemented for employees such as the molders on line 2 who were exposed to formaldehyde at 1.30 parts per million and 0.52 parts per million. Castalloy, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.1048(l)(1)(i), which was contained in OSHA inspection number 315119255, citation number 1, item number 5a and was affirmed as a final order on July 12, 2012, with respect to a workplace located at 1701 Industrial Lane, Waukesha, WI 53189.
Recent events (3)
- — F (R) $0
- — C (R) $13860
- — Z (R) $13860
1910.132 E
- Issued
- May 15, 2013
- Abate by
- May 21, 2013
- Penalty
- Initial $0 · Current $0
General-duty citation text
29 CFR 1910.132(e): The employer did not ensure that employees were not using defective or damaged personal protective equipment in the workplace: (a) The metal pourer wore the bump cap that was defective in that holes had been burned in the bump cap and old earplugs stuck in those holes.
Recent events (3)
- — F (O) $0
- — C (O) $0
- — Z (O) $0
1910.212 A01
- Issued
- May 15, 2013
- Abate by
- May 21, 2013
- Penalty
- Initial $0 · Current $0
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: (a) The guard on the Roberts Sinto U150 molding machine, serial number 20125, had the padlock installed but not locked and had the key for the lock left inside the lock.
Recent events (3)
- — F (O) $0
- — C (O) $0
- — Z (O) $0
1910.303 B02
- Issued
- May 15, 2013
- Abate by
- May 15, 2013
- Penalty
- Initial $0 · Current $0
General-duty citation text
29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling: (a) The electric control panel door remained open for the IMF pit conveyor while the equipment was in operation.
Recent events (3)
- — F (O) $0
- — C (O) $0
- — Z (O) $0
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Source
This record is reproduced from the U.S. Department of Labor Open Data API (OSHA inspection dataset). The original IMIS detail view is available at OSHA's Establishment Search for activity number 337589618.
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