OSHA Inspection: DOMESTIC CASTING COMPANY, LLC

Issued

Jul 9, 2013

Abate by

Aug 13, 2013

Penalty

Initial $3,850 · Current $2,888 Reduced

General-duty citation text

29 CFR 1910.37(b)(2): Each exit was not clearly visible and marked by a sign reading "Exit":    a)  Shot Blast Area - On or about March 7, 2013, the door off of the Shotblast area was not labeled "Exit."       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

Jul 9, 2013

Abate by

Aug 26, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(4): Signs were not posted along the exit access indicating the direction of travel to the nearest exit and exit discharge when the direction of travel to the exit or exit discharge was not immediately apparent:    a)  In the Foundry - On or about February 19, 2013, where the direction of travel to the exit was not immediately apparent, the employer had not ensured that the direction of travel to the nearest exit was plainly marked with signs.      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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 258790109130

General-duty citation text

29 CFR 1910.94(a)(7): Dust was permitted to accumulate on the floor or on ledges outside of an abrasive-blasting enclosure, and dust spills were not cleaned up promptly. Aisles and walkways were not kept clear of steel shot or similar abrasive which may have created a slipping hazard:    a)  Shot Blast Area - On or about March 7, 2013, the employer had not ensured that aisles and walkways were kept clear of steel shot; employees were exposed to the hazard of slipping and falling around abrasive blasting enclosures, operating forklifts, and parts bins.      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

Jul 9, 2013

Abate by

Sep 26, 2013

Penalty

Initial $5,390 · Current $4,042 Reduced

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 administrative or engineering controls were not utilized:    a)  System II Shakeout Area - An employee, operating the OM Shaker, was sampled for occupational noise exposure on March 7, 2013, for 467 minutes, at a level of approximately 416% of the allowable dose, using the 90 dB criterion level.  This was equivalent to an exposure of approximately 100.3 dBA 8-hr. TWA, in excess of the OSHA PEL, which was capable of causing hearing loss.  Zero exposure was assumed for the unsampled time period of 13 minutes.  The employer did not ensure that feasible engineering and administrative controls, including but not limited to the installation of barriers, baffles, sound-absorbing materials, or the use of employee rotation, were implemented to reduce employees' exposure to occupational noise.       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. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Jul 9, 2013

Abate by

Sep 26, 2013

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 81108111

General-duty citation text

29 CFR 1910.95(g)(8)(ii)(B): Unless a physician determines that the standard threshold shift is not work-related or aggravated by occupational noise exposure, the employer did not ensure, when a standard threshold shift occurs, that for employees already using hearing protectors, employees be refitted and retrained in the use of hearing protectors and provided with hearing protectors offering greater attenuation if necessary:    a)  Furnace Area - An employee, operating the Furnaces, was sampled for occupational noise exposure on February 19, 2013, for 458 minutes, at a level of approximately 214% of the allowable dose, using the 90 dB criterion level.  This was equivalent to an exposure of approximately 95.5 dBA 8-hr. TWA, in excess of the OSHA PEL.  Zero exposure was assumed for the unsampled time period of 22 minutes.  The employer did not retrain or refit an employee in the use of hearing protection or provide hearing protectors offering greater attenuation when that employee was exposed to occupational noise above the Permissible Exposure Limit and sustained an age-adjusted Standard Threshold Shift average of 11.33 dB in his right ear.      b)  Core Room - A Machine Operator employee was sampled for occupational noise exposure on February 19, 2013, for 429 minutes, at a level of approximately 101% of the allowable dose, using the 80 dB criterion level.  This was equivalent to an exposure of approximately 90.1 dBA 8-hr. TWA, in excess of the OSHA AL.  Zero exposure was assumed for the unsampled time period of 51 minutes.  The employer did not retrain or refit an employee in the use of hearing protection or provide hearing protectors offering greater attenuation when that employee was exposed to occupational noise above the Action Level and sustained an age-adjusted Standard Threshold Shift average of 11.33 dB in his left ear.     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

Jul 9, 2013

Abate by

Sep 26, 2013

Penalty

Initial $5,390 · Current $4,042 Reduced

Hazardous substances 2260229090109130

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:    Core Room - On or about February 19, 2013, the employer had not established and implemented a written respiratory protection program for employees with exposure-required use of the tight-fitting half-face elastomeric facepiece air purifying respirators, including, but not limited to a pre-use medical fitness evaluation evaluations to determine the employee's ability to use a respirator; a pre-use and annual respiratory protection fit testing; determining a conservative respirator cartridge change-out schedule; and ensuring pre-use and annual training in respirator proper use and limitations, care for, cleaning, disinfecting, and storage of, respiratory hazards requiring respirator use, and possible health hazards involved in using respiratory protective equipment for employees operating enclosed mold core-making machines to form the interior voids of cast iron parts.      a)  An employee, operating an enclosed mold core machine to form the interior void of cast iron parts, was exposed to Sulfur Dioxide at a Time Weighted Average (TWA) of 12.17 parts per million particles of air (ppm), 2.43 times the limit of 5 ppm, the limit established to prevent respiratory injury, while operating an enclosed mold core machine to form the interior void of cast iron parts. The sampling was performed for 441 minutes during one shift on February 19, 2013.  Zero exposure was assumed for the unsampled time period of 39 minutes.        b)  An employee, operating an enclosed mold core machine to form the interior void of cast iron parts, was exposed to Sulfur Dioxide at a Time Weighted Average (TWA) of 6.02 parts per million particles of air (ppm), 1.20 times the limit of 5 ppm, the limit established to prevent respiratory injury, while operating an enclosed mold core machine to form the interior void of cast iron parts. The sampling was performed for 429 minutes during one shift on February 19, 2013.  Zero exposure was assumed for the unsampled time period of 51 minutes.        c)  An employee, operating an enclosed mold core machine to form the interior void of cast iron parts, was exposed to Sulfur Dioxide at a Time Weighted Average (TWA) of 5.86 parts per million particles of air (ppm), 1.17 times the limit of 5 ppm, the limit established to prevent respiratory injury, while operating an enclosed mold core machine to form the interior void of cast iron parts. The sampling was performed for 425 minutes during one shift on February 19, 2013.  Zero exposure was assumed for the unsampled time period of 55 minutes.      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. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Jul 9, 2013

Abate by

Feb 8, 2014

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.134(i)(5)(iii): The compressor did not have suitable in-line air-purifying sorbent beds and filters to further ensure breathing air quality:    a)  Air Compressor House - On or about January 18, 2013, the employer had not ensured that the compressor system had in-line sorbent beds and filters to ensure breathing air quality, including but not limited to desiccant beds to dehumidify the breathing air supplied to the Cleaning Department's employees, cutting and grinding cast iron parts while wearing mandatory-use 3M Headgear L-Series supplied air hood respirators to maintain their exposure to air contaminants, including but not limited to Respirable Silica (Crystalline Quartz), Respirable Dust (PNOR, Particulates Not Otherwise Regulated), and Iron Oxide, within the Permissible Exposure Limits (PELs) prescribed in 29 CFR Part 1910.1000 or other sections of this part.    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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 2260229090109130

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)  Core Room - On or about February 19, 2013, the employer, producing cast iron parts, had allowed employees to consume food and beverages in the Core Room, an area exposed to Sulfur Dioxide gas and caustic soda (Sodium Hydroxide), 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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.215(a)(2): Abrasive wheel(s) used on grinding machinery were not provided with safety guard(s) which covered the spindle end, nut, flange projections:    a)  Cleaning Department - On or about January 18, 2013, employees, cutting and grinding cast iron parts at grinder station #1, were using a large bench grinder with 9-inch diameter by one quarter-inch width cut-off wheel with the spindle end, nut, and flange projections uncovered.     b)  Cleaning Department - On or about January 18, 2013, employees, cutting and grinding cast iron parts at grinder station #3, were using a large bench grinder with 9-inch diameter by one quarter-inch width cut-off wheel with the spindle end, nut, and flange projections uncovered.    c)  Cleaning Department - On or about January 18, 2013, employees, cutting and grinding cast iron parts at grinder station #4, were using a large bench grinder with 9-inch diameter by one quarter-inch width cut-off wheel with the spindle end, nut, and flange projections uncovered.    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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.215(a)(4): Grinding machinery was not used with work rest(s) to support offhand grinding work:  a)  Cleaning Department - On or about January 18, 2013, at least 5 employees, cutting and grinding cast iron parts, were using 5 different large bench grinders with 9-inch diameter by one and one half (1.5) inch width abrasive wheels without work rests.    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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.215(b)(9): The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch:  a)  Cleaning Department - On or about January 18, 2013, at least 5 employees, cutting and grinding cast iron parts, were using 5 different large bench grinders with 9-inch diameter by one and one half (1.5) inch width abrasive wheels without tongue guards.      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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $3,850 · Current $2,888 Reduced

General-duty citation text

29 CFR 1910.303(c)(3)(i): Conductors were not spliced or joined with splicing devices identified for the use or by brazing, welding, or soldering with a fusible metal or alloy. Soldered splices were not first spliced or joined to be mechanically and electrically secure without solder and then soldered. All splices and joints and the free ends of conductors were not covered with an insulation equivalent to that of the conductors or with an insulating device identified for the purpose:    a)  Air Compressor House - On or about January 18, 2013, employees, using the industrial fan to cool the oil-lubricated breathing air compressors, were exposed to the electrical shock hazard of the industrial fans electrical cord being spliced in a damp location with wire nuts and electrical tape in that the splice was not brazed, welded, or soldered; mechanically and electrically secured without solder; or covered with an insulation equivalent to that of the conductors or an insulating device identified for the purpose.      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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(1)(iv): Flexible cords and/ or cables were used for purposes prohibited by paragraphs (A) through (F) of 29 CFR 1910.305(g)(1)(iv):  a)  C & D Molding Area - On or about February 6, 2013, the employer used a flexible cord in place of permanent wiring to power the heat lamp heating the pneumatic pressure line near the operator's station; employees, operating the end Spo cope and drag molding machine, were exposed to fire, electrical burn, and electrical shock hazards while using the machine.    b)  C & D Molding Area - On or about February 6, 2013, the employer attached flexible cords to 2 interior walls in order to power the heat lamp heating the pneumatic pressure line near the operator's station; employees, operating the end Spo cope and drag molding machine, were exposed to fire, electrical burn, and electrical shock hazards while using the machine.    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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords and cables were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws:  a)  C & D Molding Area - On or about February 6, 2013, employees, operating the end Spo cope and drag molding machine, were exposed to electrical burn and electrical shock hazards in that the outer insulation at the flexible cord's connection to the heat lamp, heating the air line on the machine, was pulled so that there was no longer outer insulation or strain relief provided to prevent tension from being directly transmitted to joints or terminal screws.  b)  C & D Molding Area - On or about February 6, 2013, employees, operating the end Spo cope and drag molding machine, were exposed to fire, electrical burn, and electrical shock hazards in that the outer insulation by the outlet plug of the flexible cord for the heat lamp was pulled so that there was no longer strain relief provided to prevent tension from being directly transmitted to joints or terminal screws.   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

Jul 9, 2013

Abate by

May 31, 2014

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 2290

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of Sulfur Dioxide listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 5 parts per million particles of air (ppm):    a)  Core Room - An employee, operating an enclosed mold core machine to form the interior void of cast iron parts, was exposed to Sulfur Dioxide at a Time Weighted Average (TWA) of 12.17 parts per million particles of air (ppm), 2.43 times the limit of 5 ppm, the limit established to prevent respiratory injury, while operating an enclosed mold core machine to form the interior void of cast iron parts. The sampling was performed for 441 minutes during one shift on February 19, 2013.  Zero exposure was assumed for the unsampled time period of 39 minutes.        b)  Core Room - An employee, operating an enclosed mold core machine to form the interior void of cast iron parts, was exposed to Sulfur Dioxide at a Time Weighted Average (TWA) of 6.02 parts per million particles of air (ppm), 1.20 times the limit of 5 ppm, the limit established to prevent respiratory injury, while operating an enclosed mold core machine to form the interior void of cast iron parts. The sampling was performed for 429 minutes during one shift on February 19, 2013.  Zero exposure was assumed for the unsampled time period of 51 minutes.        c)  Core Room - An employee, operating an enclosed mold core machine to form the interior void of cast iron parts, was exposed to Sulfur Dioxide at a Time Weighted Average (TWA) of 5.86 parts per million particles of air (ppm), 1.17 times the limit of 5 ppm, the limit established to prevent respiratory injury, while operating an enclosed mold core machine to form the interior void of cast iron parts. The sampling was performed for 425 minutes during one shift on February 19, 2013.  Zero exposure was assumed for the unsampled time period of 55 minutes.      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

Jul 9, 2013

Abate by

May 31, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 2290

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 employer did not implement feasible administrative and engineering controls to reduce employees' exposure to sulfur dioxide, as evident by the fact that employees were exposed to sulfur dioxide in excess of the Permissible Exposure Limit, and the employer did not ensure the enclosures for the sulfur dioxide core-making machines were maintained to prevent fugitive emissions, and did not ensure that the local exhaust ventilation system was maintained, prevent dangerous levels of sulfur dioxide gas from reaching employees' breathing zones, on or about February 19, 2013.    Among other feasible means of abatement the employer could ensure that the sulfur dioxide core-making machine enclosures' caustic soda (Sodium Hydroxide) scrubber system functions effectively enough to reduce the Sulfur Dioxide exposure below the Permissible Exposure Limit and/or ensure that the exhaust ventilation for the sulfur dioxide core-making area is sufficient to effectively reduce the Sulfur Dioxide exposure below the Permissible Exposure Limit.      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

Jul 9, 2013

Abate by

Aug 4, 2015

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of Respirable Dust and Iron Oxide listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 5 milligrams per cubic meter (mg/m(3)) and 10 mg/m(3), respectively:    a)  Cleaning Department - An employee, cutting and grinding cast iron parts, was exposed to Respirable Dust (PNOR, Particulates Not Otherwise Regulated) at a Time Weighted Average (TWA) of 5.37 milligrams per cubic meter (mg/m(3)), 1.07 times the limit of 5 mg/m(3), the limit established to prevent respiratory injury, while operating enclosed abrasive blasting machines to clean cast iron parts. The sampling was performed for 393 minutes during one shift on March 7, 2013.  Zero exposure was assumed for the unsampled time period of 87 minutes.     b)  Cleaning Department - An employee, cutting and grinding cast iron parts, was exposed to airborne Iron Oxide at a Time Weighted Average (TWA) of 14.84 milligrams per cubic meter (mg/m(3)), 1.48 times the limit of 10 mg/m(3), the limit established to prevent respiratory injury, while using a bench grinder with 2 grinding wheels to clean cast iron parts. The sampling was performed for 405 minutes during one shift on March 7, 2013.  Zero exposure was assumed for the unsampled time period of 75 minutes.       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

Jul 9, 2013

Abate by

Aug 4, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1520258790109130

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)  Cleaning Department - The employer did not implement feasible administrative and engineering controls to reduce employees' exposure to respirable dust (PNOR, Particulates Not Otherwise Regulated) and iron oxide, as evident by the fact that employees were exposed to respirable dust and iron oxide in excess of the PEL, and the employer did not ensure the grinding station local exhaust ventilation systems were maintained to prevent fugitive emissions and did not ensure that exhaust ventilation for the 9-inch wheeled bench grinders exhaust ports was provided to prevent dangerous levels of airborne respirable dust and iron oxide from reaching employees' breathing zones, on or about March 7, 2013.    Among other feasible means of abatement the employer could install a water misting system to humidify the air immediately over the overexposed employees to conglomerate the dust into larger particles before they are inhaled, install a wet grinding system to assist in eliminating the evolution of dust both respirable and metallic, attach the grinders to the dust collection system drawing a minimum of 220 cubic feet per minute (for a grinding wheel 9 inches in diameter and one and one half (1.5) inch in width, higher flows for larger wheels as prescribed in 29 CFR 1910.94 Ventilation) using the ports at the rear bottom of the grinding wheel guards designed for that purpose, increase the draw of their dust collection system to equal a minimum of 220 cubic feet per minute (for a grinding wheel 9 inches in diameter and one and one half (1.5) inch in width, higher flows for larger wheels as prescribed in 29 CFR 1910.94 Ventilation) at the surface planes of the grinding area as if it were an enclosed box, and/or install adaptable local exhaust hoods for each bench grinder that are located as close as possible to the operation.       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

Jul 9, 2013

Abate by

Aug 4, 2015

Penalty

Initial $3,850 · Current $2,888 Reduced

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.1000(c): Employees were exposed to Respirable Silica (Crystalline Quartz) in excess of the 8-hour Time Weighted Average concentration calculated using the formula listed in Table Z-3:    a)  Shot Blast - An employee, operating Wheelabrator and Pangborn enclosed abrasive blasting machines to clean the exterior of cast iron parts, was exposed to respirable dust containing 10.2% crystalline silica (quartz) at a Time Weighted Average (TWA) of 2.56 milligrams per cubic meter (mg/m(3)), 3.13 times the calculated permissible exposure limit (PEL) of .82 mg/m(3).  The sampling was performed for 421 minutes during one shift on February 19, 2013, and zero exposure was assumed for the unsampled time period of 59 minutes.         b)  Shot Blast - An employee, operating Wheelabrator and Pangborn enclosed abrasive blasting machines to clean the exterior of cast iron parts,  was exposed to respirable dust containing 9.28% crystalline silica (quartz) at a Time Weighted Average (TWA) of 1.52 milligrams per cubic meter (mg/m(3)), 1.71 times the calculated permissible exposure limit (PEL) of .89 mg/m(3).  The sampling was performed for 419 minutes during one shift on February 19, 2013, and zero exposure was assumed for the unsampled time period of 61 minutes.      c)  Cleaning Department - An employee,  cutting and grinding cast iron parts, was exposed to respirable dust containing 5.5% crystalline silica (quartz) at a Time Weighted Average (TWA) of 2.40 milligrams per cubic meter (mg/m(3)), 1.80 times the calculated permissible exposure limit (PEL) of 1.33 mg/m(3).  The sampling was performed for 399 minutes during one shift on March 7, 2013, and zero exposure was assumed for the unsampled time period of 81 minutes.         d)  Cleaning Department - An employee, cutting and grinding cast iron parts, was exposed to respirable dust containing 4.1% crystalline silica (quartz) at a Time Weighted Average (TWA) of 3.37 milligrams per cubic meter (mg/m(3)), 2.05 times the calculated permissible exposure  limit (PEL) of 1.64 mg/m(3). The sampling was performed for 393 minutes during one shift on March 7, 2013, and zero exposure was assumed for the unsampled time period of 87 minutes.        e)  Cleaning Department - An employee, cutting and grinding cast iron parts, was exposed to respirable dust containing 3.1% crystalline silica (quartz) at a Time Weighted Average (TWA) of 3.36 milligrams per cubic meter (mg/m(3)), 1.71 times the permissible exposure limit (PEL) of 1.96 mg/m(3), the limit established to prevent Silicosis, while using a bench grinder with 2 grinding wheels to clean cast iron parts. The sampling was performed for 394 minutes during one shift on March 7, 2013.  Zero exposure was assumed for the unsampled time period of 86 minutes.     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

Jul 9, 2013

Abate by

Aug 4, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1520258790109130

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)  Shot Blast - The employer did not implement feasible administrative and engineering controls to reduce employees' exposure to silica, as evident by the fact that employees were exposed to Respirable Silica (Crystalline Quartz) in excess of the calculated permissible exposure limit (PEL), and the employer did not ensure the enclosures for the Wheelabrator and Pangborn abrasive blasting machines were maintained to inhibit fugitive emissions, and did not ensure that the local exhaust ventilation system was maintained in order to prevent dangerous levels of airborne silica from reaching employees' breathing zones, on or about February 19, 2013.    b)  Cleaning Department - The employer did not implement feasible administrative and engineering controls to reduce employees' exposure to silica, as evident by the fact that employees were exposed to Respirable Silica (Crystalline Quartz) in excess of the calculated permissible exposure limit (PEL), and the employer did not ensure that the local exhaust ventilation system was maintained to inhibit fugitive emissions and prevent dangerous levels of airborne silica from reaching employees' breathing zones, on or about March 7, 2013.    Shot Blast - Among other feasible means of abatement the employer could install a water misting system to humidify the air immediately over the overexposed employees to conglomerate the dust into larger particles before they are inhaled, ensure that the abrasive-cleaning enclosures have a continuous inward flow of air maintained at all openings, and/or ensure that the exhaust ventilation for the abrasive-cleaning enclosures conform to American National Standard Fundamentals Governing the Design and Operation of Local Exhaust Systems, Z9.2-1960 and ANSI Z33.1-1961 specifications.        Cleaning Department - Among other feasible means of abatement the employer could install a water misting system to humidify the air immediately over the overexposed employees to conglomerate the dust into larger particles before they are inhaled, install a wet grinding system to assist in eliminating the evolution of dust both respirable and metallic, attach the grinders to the dust collection system drawing a minimum of 220 cubic feet per minute (for a grinding wheel 9 inches in diameter and one and one half (1.5) inch in width, higher flows for larger wheels as prescribed in 29 CFR 1910.94 Ventilation) using the ports at the rear bottom of the grinding wheel guards designed for that purpose, increase the draw of their dust collection system to equal a minimum of 220 cubic feet per minute (for a grinding wheel 9 inches in diameter and one and one half (1.5) inch in width, higher flows for larger wheels as prescribed in 29 CFR 1910.94 Ventilation) at the surface planes of the grinding area as if it were an enclosed box, and/or install adaptable local exhaust hoods for each bench grinder that are located as close as possible to the operation.      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

Jul 9, 2013

Abate by

Aug 4, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1520258790109130

General-duty citation text

29 CFR 1910.94(b)(2): Where dry grinding, dry polishing or buffing was performed, and employee exposure, without regard to the use of respirators, exceeded the permissible exposure limits prescribed in 1910.1000 or other sections of this part, a local exhaust ventilation system was not provided and used to maintain employee exposures within the prescribed limits:    a)  Cleaning Department - The employer had not provided a local exhaust ventilation system, drawing a minimum of 220 cubic feet per minute (for a grinding wheel 9 inches in diameter and one and one half (1.5) inch in width, higher flows for larger wheels) to maintain employee exposures to air contaminants, including but not limited to Respirable Silica (Crystalline Quartz), Respirable Dust (PNOR, Particulates Not Otherwise Regulated), and Iron Oxide within the limits prescribed in 29 CFR Part 1910.1000.      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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $2,310 · Current $1,733 Reduced

Hazardous substances 00701080152021502290

General-duty citation text

29 CFR 1910.1200(f)(5)(i): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the identity of the hazardous chemical(s) contained therein:    a) Core Room - On or about February 19, 2013, the employer had not identified the contents in the coffee containers, containing core sand and the small plastic jar, containing lubricant.        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

Jul 9, 2013

Abate by

Jul 30, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 00701080152021502290

General-duty citation text

29 CFR 1910.1200(f)(5)(ii): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the appropriate hazard warnings:   a) Core Room - On or about February 19, 2013, the employer had not identified the appropriate hazard warnings for the contents of the coffee containers, containing core sand and the small plastic jar, containing lubricant.    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

Jul 9, 2013

Abate by

Sep 26, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 00701080152021502290

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)  In the Foundry - On or about March 7, 2013, the employer had not provided employees with effective information and training on the physical and health hazards associated with the hazardous chemicals to which they were exposed, including but not limited to oxygen, acetylene, welding fumes, toluene, xylenes, ethyl benzene, core sand, and molding sand; and to which they were overexposed, including but not limited to respirable silica, respirable dust (PNOR, Particulates Not Otherwise Regulated), Iron Oxide, and Sulfur Dioxide.      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.