OSHA Inspection: DOMESTIC CASTING COMPANY, LLC

Issued

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $5,390 · Current $3,773 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 hazards while lifting loads with below the hook lifting devices:    (a) Spreader Bar Below the Hook Lifting Device At The SPO Machine -  Employees were exposed to struck by hazards when they made up to 200 lifts per day with a below the hook lifting device consisting of a spreader bar and two vertical lifter bars used with a pneumatic under hung chain hoist to lift copes and drags weighing up to 300 pounds.  The parts of the lifting device did not have a load rating marked on the main structure, or on an attached tag, and the individual hangers were not marked with their individual rated loads. The lifting device was not marked with the manufacturer's name, serial number.  The lifter did not have a product safety label. The hoist hook was attached directly to the spreader bar gusset and the gusset plate steel was showing evidence of wear. The employer did not require frequent and periodic inspections of the lifting device, on or about August 13, 2013.    (b) Spreader Bar Below The Hook Lifting Device At The International Machine - Employees were exposed to struck by hazards when they made up to 50 lifts per day with a below the hook lifting device consisting of a spreader bar and two vertical ½ inch wire rope lifters used with an electric under hung chain hoist to lift copes and drags weighing up to 500 pounds.  The parts of the lifting device did not have a load rating marked on the main structure or on an attached tag, the individual hangars were not marked with their individual rated loads. The lifting device was not marked with the manufacturer's name, serial number.  The lifter did not have a product safety label. The spreader bar was welded together from two shorter bars. The employer did not require frequent and periodic inspections of the lifting device, on or about August 13, 2013.     (c) Cantilevered Tote Lifter At Small Shake Out - An employee was exposed to struck by hazards when he used the below the hook lifting device throughout the day to lower empty totes and raise totes full of castings weighing up to 2800 pounds.  The lifting device did not have a load rating marked on the main structure or on an attached tag.  The lifting device was not marked with the manufacturer's name, serial number.  The lifter did not have a product safety label. Weld repairs made to the device were not in accordance with ANSI /AWS D14.1, a weld repair along the top horizontal spreader was cracked halfway through the plate patch.  The employer did not require frequent and periodic inspections of the lifting device, on or about August 19, 2013.    (d)  Platform Lifter At Core Room Mezzanine - Employees were exposed to struck by hazards when they used the below the hook lifting device to raise and lower cores and core boxes from the shop floor to the mezzanine.  The lifting device did not have a load rating marked on the main structure or on an attached tag.  The lifting device was not marked with the manufacturer's name, serial number.  The lifter did not have a product safety label.  The employer did not require frequent and periodic inspections of the lifting device, on or about August 19, 2013.    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

Feb 6, 2014

Abate by

May 30, 2014

Penalty

Initial $5,390 · Current $3,773 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 the employer failed to maintain underhung cranes in a safe condition, employees operated underhung cranes with broken, damaged or missing parts and/or missing or bypassed safety devices and were exposed to crushing injuries and burn injuries from uncontrolled loads lifted by the underhung cranes and hoists:        UNDERHUNG CRANES: The employer did not ensure that broken, damaged or missing parts and/or missing or bypassed safety devices were repaired before allowing employees to operate under hung cranes.  Employees used these cranes to move ladles of hot metal and other loads of iron in the foundry and were exposed to struck-by hazards and hazards of splashed molten iron, observed on or about August 13, 2013.    (a) Yale, Under Hung Wire Rope Bridge Magnet Crane #45 - The hook did not have a safety latch, the hoist brake was not working, most of the parts were missing and the load drifted down during operation, the pendant control box was not marked with identification of all of the functions, the runway and festoon wires were damaged, the contactor panel door was open above the Ajax room, the 230 VAC  3 phase contactors were not mounted inside the cabinet, they were laying on the lid creating a shock and fire hazard.       (b) Electro Lift Under Hung Wire Rope Monorail Hot Metal Crane #36 - The pendant did not have a strain relief, the directional markings on the pendant were not all readable, the power circuit limit switch was removed, the geared limit switch was not working.         (c) Electro Lift Under Hung Wire Rope Monorail Hot Metal Crane  #39 ? The pendant did not have a strain relief, the bottom block was missing 3 of 8 assembly bolts.         (d) Electro Lift Under Hung Wire Rope Monorail Hot Metal Crane #41 - The strain relief chain was not connected to the pendant, the directional markings on the pendant were unreadable and a bolt was missing from the bottom block.        (e) R & M Under Hung Wire Rope Monorail Hunter Turntable Hot Metal Crane # 38 ? The pendant did not have a strain relief and was dragging on the ground, the insulation on the pendant cord was burned through, the wire rope was kinked and there was no safety latch on the hook.        (f) North American Under Hung Bridge Osborne Hot Metal Pour Crane ? The pendant had an open button hole that was not blanked off, exposing operators to live 110 volt current, the top part of the pendant was broken, the directional markings were not on the pendant and there was no strain relief for the pendant.        (g) Shaw Box Under Hung Wire Rope Heat Treating Oven Crane #31 - The running rope had more than six randomly distributed broken wires in six rope diameters and more than three broken wires in one strand in six rope diameters which exceeded the removal criteria, the up button in the pendant was pushed in at an angle in the pendant housing, the control wires were pulled from the strain relief of the pendant housing, direction markings were not complete on pendant and load brake made noise when lowering the hook.        (h) R & M Under Hung Wire Rope Bridge Crane in Old Maintenance - None of the ten buttons on the pendant had legible directional markings, the running rope had kinks and more than three broken wires in one strand in six rope diameters which exceeded the removal criteria.       UNDERHUNG HOISTS: The employer did not ensure that frequent inspections were performed by the operators or other designated personnel.  Employees used these hoists to lift a variety of loads including castings, copes and drags, in the foundry and were exposed to struck by hazards and crushing hazards, observed on or about August 13, 2013.      (i) Gardner Denver Pneumatic Chain Hoist #21 at CB22 Core machine - There were no direction markings on the control lever, there were no ropes on directional control lever, the safety latch was sprung out of hook and the capacity of hoist (2200 pounds) exceeded the capacity of the jib (500 pounds).         (j) Gardner Denver Pneumatic Chain Hoist #3 at Core Room Mezzanine - The hook safety latch was bent and out of adjustment and could not effectively contain the load, the capacity of the hoist (1 ton) exceeded the capacity of the jib (1/2 ton) and there were no directional markings on the control lever or ropes.        (k) ARO Pneumatic Chain Hoist #14 at the Small Shot Blast Shaker - The hook safety latch was missing, there were no directional markings on the control lever or ropes, the vertical I beam on jib was folded and severely bent, there was no load rating marked on the jib and the hoist capacity was 1100 pounds the bottom block capacity was 2200 pounds.        (l) Gardner Denver Pneumatic Chain Hoist #60 at the Rumbler Room Large Grind Area - The hook safety latch was missing, there were no directional markings on the control lever or ropes, the jib hinge pin was excessively worn and the capacity of the hoist (2200 pounds) exceeded the capacity of the jib (1/2 ton).        (m) Harrington Electric Chain Hoist #133 at the SPO Punch Out - The hook safety latch was missing.        (n) Underhung Pneumatic Chain Hoist at SPO - The hook had two safety latches installed but no spring.        (o) Gardner Denver Pneumatic Chain Hoist #32 at Osborn Shakeout - The hook safety latch was missing.        (p) Gardner Denver Pneumatic  Chain Hoist at Large Shot Blast - There was no pendant warning label, the jib has no weight capacity markings, the hoist capacity is 2200 pounds and capacity of the bottom block was worn off both sides.        (q) Budgit Electric Chain Hoist at Small Shakeout Area - The hook safety latch was bent and outside the hook and the pendant did not have a strain relief.       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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $3,080 · Current $2,156 Reduced

General-duty citation text

29 CFR 1910.22(c): Covers and/or guardrails were not provided to protect personnel from the hazards of open pits, tanks, vats, ditches, etc:    (a) Roof of Foundry - Employees who walked to the tower to perform maintenance walked through a 36 inch gap between the chain link fence and the scrap pit and were exposed to a fall of 10 feet into the scrap pit, on or about October 22, 2013.    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

Feb 6, 2014

Abate by

Apr 15, 2014

Penalty

Initial $3,850 · Current $2,695 Reduced

General-duty citation text

29 CFR 1910.23(a)(2): Ladderway floor opening(s) or platform(s) were not guarded by a standard railing with standard toe board(s) on all exposed sides (except at the entrance to opening) with passage through the railing either provided with a swinging gate or so offset that a person could walk directly into the opening:    (a) Tower - The employer did not ensure that the vertical ladder landing platform in the tower had a swinging gate or was offset to prohibit a person from walking into the opening.  Employees who worked in the tower to perform maintenance and servicing of equipment were exposed to a 30 foot fall down the vertical ladder opening to the foundry below, on or about September 22, 2013.      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

Feb 6, 2014

Penalty

Initial $5,390 · Current $3,773 Reduced

General-duty citation text

29 CFR 1910.23(d)(1)(i): Flight(s) of stairs with four or more risers, less than 44 inches wide and having both sides enclosed, were not equipped with at least one standard handrail, preferably on the right side descending:    (a) Pit Below Magnet Belt System 1 - Employees used a set of stairs to enter the pit below the magnet belt to clean at the end of each shift.  There was no handrail provided on either side of the stairs, the moving conveyor belt was located adjacent to the stairs on the right side descending.  Employees were exposed to a slip, trip, fall and caught between hazards, on or about October 22, 2013.     No abatement certification or documentation required.

Issued

Feb 6, 2014

Penalty

Initial $3,850 · Current $2,695 Reduced

General-duty citation text

29 CFR 1910.24(b): Fixed stairs were not provided for access from one structure level to another where operations necessitated regular travel between levels, and for access to operating platforms at any equipment which requires attention routinely during operations:    (a) Small Blast Shaker Conveyor - Employees worked from a 3 foot X 4 foot platform that was 26 inches high to sort castings on the conveyor.  There were no stairs provided for employees to use to access the work platform and employees were exposed to strains and sprains, on or about October 22, 2013.     No abatement certification or documentation required.

Issued

Feb 6, 2014

Penalty

Initial $3,080 · Current $2,156 Reduced

General-duty citation text

29 CFR 1910.24(f): Rise height and tread width were not uniform throughout any flight of stairs including any foundation structure used as one or more treads of the stairs and the nosings were not of nonslip finish:    (a) Stairs To Tower - The front portion of the wooden tread of the 9th step in the 19 step industrial stairway which leads to the tower was broken off.  Employees were exposed to a tripping hazard when they ascended or descended the stairs to perform maintenance and repairs inside the tower, on or about October 22, 2013.      No abatement certification or documentation required.

Issued

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $2,310 · Current $1,617 Reduced

General-duty citation text

29 CFR 1910.27(c)(4): The employer did not install fixed ladders with at least 7 inches of clearence from the centerline of the rung to the nearest permanent object in the back of the ladder.     (a) Fixed Ladder West Wall Of The AJAX Room - The bottom of the ladder was pushed in close to the wall, the bottom rung had 0 to 3 inches of clearance and the second rung had 0 to 4 inches of clearance from the centerline of the rung to the nearest permanent object behind the ladder.  Employees climbed the ladder to access the control box for the magnet crane, on or about November 12, 2013.     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

Feb 6, 2014

Abate by

May 30, 2014

Penalty

Initial $5,390 · Current $0 Reduced

General-duty citation text

29 CFR 1910.178(o)(1): The employer did not ensure that only stable or safely arranged loads were handled:    (a) Grinding Department - Employees moved metal bins full of castings around in the grinding department and to the heat treating ovens.  The bins are damaged and split open and are a hazard when moved around on the uneven floor by forklifts.  Employees are exposed to injury from unstable loads falling from the forks of forklifts, on or about August 14, 2013.    (b) Foundry - Employees transport ladles of hot metal from the furnace to the pouring areas on the forks of a Toyota forklift.  The loads are not secured to the forks or carriage and the floor of the foundry is uneven.  Employees are exposed to injury from unstable loads of hot metal falling from the forks of forklifts, on or about December 11, 2013.     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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $3,850 · Current $0 Reduced

General-duty citation text

29 CFR 1910.179(b)(5): The rated load of the crane was not plainly marked on each side of the crane, and when the crane had more than one hoisting unit, each hoist did not have its rated load marked on it or its load block and the marking was not clearly legible from the ground or floor.    (a) Whiting Shakeout 5 Ton Double Girder Trolley Crane - The rated load was not marked on the bottom block of the Whiting Crane S/N 11724. Employees lifted loads weighing up to 1800 lbs daily, and were exposed to serious injuries, on or about August 13, 2013.     (b) Whiting Pour 5 Ton Double Girder Trolley Crane - The rated load was not marked on the bottom block of the Whiting Crane S/N 11811, employees lifted loads weighing up to 3000 lbs daily and were exposed to serious injuries, on or about August 13, 2013.     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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $5,390 · Current $3,773 Reduced

General-duty citation text

29 CFR 1910.179(g)(1)(v): Pendant control box(es) were not clearly marked for identification of functions:    (a) Shakeout - The Whiting Double Girder Crane S/N 11724 had two buttons that were not marked for identification of functions.  Employees used this crane daily to lift up to 1800 lbs in the shakeout area and were exposed to movement of the load in unexpected directions, on or about August 7, 2013.    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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(2)(iii): Monthly inspections of hooks, with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected, were not performed:   (a) Whiting Shakeout 5 Ton Double Girder Trolley Crane - The employer did not ensure that a competent person conducted monthly hook inspections of Whiting Crane S/N 11724 and did not maintain certification records of the inspections. Employees lifted loads weighing up to 3000 lbs daily.  Employees were exposed to crushing injuries from falling or uncontrolled loads due to the fact that the hook did not have a safety latch, on or about August 19, 2013.    (b) Whiting Pour 5 Ton Double Girder Trolley Crane - The employer did not ensure that a competent person conducted monthly hook inspections of Whiting Crane S/N 11811 and did not maintain certification records of the inspections. Employees lifted loads weighing up to 3000 lbs daily, on or about August 13, 2013.   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

Feb 6, 2014

Abate by

Apr 15, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(l)(1): A preventive maintenance program based on the crane manufacturer's recommendations was not established:    (a) Whiting Shakeout 5 Ton Double Girder Trolley Crane - The employer did not establish a preventative maintenance program based on the manufacturer's recommendations for the Whiting Crane S/N 11724. Employees lifted loads weighing up to 3000 lbs daily.  Employees were exposed to crushing injuries from falling or uncontrolled loads due to the fact that the hook did not have a safety latch, on or about August 13, 2013.     (b) Whiting Pour 5 Ton Double Girder Trolley Crane - The employer did not establish a preventative maintenance program based on the manufacturer's recommendations for the Whiting Crane S/N 11811. Employees lifted loads weighing up to 3000 lbs daily, on or about August 13, 2013.     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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $5,390 · Current $3,773 Reduced

General-duty citation text

29 CFR 1910.179(m)(1): Monthly inspections of running rope, with a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier of the rope which was inspected, were not performed:    (a) Whiting Shakeout 5 Ton Double Girder Trolley Crane - The employer did not ensure that monthly running rope inspections of Whiting Crane S/N 11724 were conducted and did not maintain certification records of the inspections. Employees lifted loads weighing up to 3000 lbs daily, on or about August 13, 2013.     (b) Whiting Pour 5 Ton Double Girder Trolley Crane - The employer did not ensure that monthly running rope inspections of Whiting Crane S/N 11811 were conducted and did not maintain certification records of the inspection. Employees lifted loads weighing up to 3000 lbs daily, on or about August 13, 2013.     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

Feb 6, 2014

Abate by

Mar 14, 2014

Penalty

Initial $5,390 · Current $3,773 Reduced

General-duty citation text

29 CFR 1910.184(d): Sling(s) and fastenings were not inspected each day by a competent person or during use and were not removed from service when damaged or defective:    (a) Floor Shake Out - The employer did not ensure that a competent person performed daily sling inspections before use.   Employees used the alloy chain sling with the 1 ton under hung jib chain hoist to lift copes and drags weighing 300 pounds.  The alloy chain sling had excessively worn chain links and did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (b) Osborn Shake Out - The employer did not ensure that a competent person performed daily sling inspections before use.  Employees used an alloy chain sling with the #32 Gardner Denver Pneumatic chain hoist at the Osborn Shake Out area to lift castings weighing up to 300 pounds.  The alloy chain shackle was stretched out of round where to pin threads in and the hook was excessively worn and did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 13, 2013.      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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.184(e)(3)(i): A thorough periodic inspection of alloy steel chain slings was not made at least once every 12 months:  (a) Shake Out - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed. Employees used an alloy chain sling with the 1 ton under hung chain hoist to lift castings weighing up to 300 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (b) Shipping Building, Large Grinding Area - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed. An employee used an alloy chain sling with the 1/2 ton under hung chain hoist to lift castings weighing up to 300 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (c) Shipping Building, Shipping Department - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed.  An employee used an alloy chain sling with the 1 ton under hung pneumatic chain hoist to lift castings weighing up to 300 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (d) Whiting Pour Crane, Foundry - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed. Employees used an alloy chain sling with the Whiting Pour crane to lift ladles of hot metal weighing 3000 pounds to pour iron castings. The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (e) Large Blast Area - The employer did not ensure that a thorough inspection of alloy chain slings was performed.  Employees used an alloy chain sling with Gardner Denver chain hoist # 7 to lift castings weighing up to 300 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about October 22, 2013.   (f) Rumbler Room, Large Grinding Area -  The employer did not ensure that a thorough inspection of alloy chain slings was performed.  Employee used an alloy chain sling below the hook of the Gardner Denver pneumatic 2200 lb underhung chain hoist at the large grind station to lift castings weighing as much as 80 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.184(e)(3)(ii): Records of the most recent month in which each alloy steel chain sling was thoroughly inspected were not available for examination:  (a) Shake Out - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed. Employees used an alloy chain sling with the 1 ton under hung chain hoist to lift castings weighing up to 300 pounds. The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (b) Shipping Building, Large Grinding Area - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed. An employee used an alloy chain sling with the 1/2 ton under hung chain hoist to lift castings weighing up to 300 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (c) Shipping Building, Shipping Department - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed.  An employee used an alloy chain sling with the 1 ton under hung pneumatic chain hoist to lift castings weighing up to 300 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (d) Whiting Pour Crane, Foundry - The employer did not ensure that a thorough periodic inspection of alloy chain slings was performed. Employees used an alloy chain sling with the Whiting Pour crane to lift ladles of hot metal weighing 3000 pounds to pour iron castings. The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  (e) Large Blast Area -The employer did not ensure that a thorough inspection of alloy chain slings was performed.  Employees used an alloy chain sling with Gardner Denver chain hoist # 7to lift castings weighing up to 300 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about October 22, 2013.   (f) Rumbler Room, Large Grinding Area -  An employee used an alloy chain sling below the hook of the Gardner Denver pneumatic 2200 lb underhung chain hoist at the large grind station to lift castings weighing as much as 80 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.  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

Feb 6, 2014

Penalty

Initial $5,390 · Current $3,773 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): The point of operation of machinery was not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s):    (a)    Breezeway - The cardboard compactor could be cycled with the loading door open.  Employees were subject to potential amputation at the point of operation when the ram traveled down to compress the cardboard, on or about August 6, 2013.    No abatement certification or documentation required.

Issued

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $5,390 · Current $3,773 Reduced

General-duty citation text

29 CFR 1910.333(a)(2): Where exposed live parts were not deenergized (i.e., for reasons of increased or additional hazards or infeasibility), other safety-related work practices were not used to protect employees who could be exposed to the electrical hazards involved:    (a) Magnet Crane Control Panel - Employees worked on the contactors for the magnet crane while the circuit was energized.  The employer did not ensure that the employee wore arc flash rated personal protective equipment.  The emloyee was exposed to live 220 volt A/C current at the contactors, on or about November 12, 2013.    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

Feb 6, 2014

Abate by

May 30, 2014

Penalty

Initial $10,780 · Current $7,546 Reduced

General-duty citation text

29 CFR 1910.23(c)(1): Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) and toeboards:    (a)  Roof of Ajax Room - Employees worked on the roof of the Ajax room to inspect and service the Magnet crane control panel and were exposed to a fall of 8 feet to the ground below, on or about November 12, 2013.    The Domestic Casting Company, LLC was previously cited for a violation of this occupational safety and health standard or its equivalent standard, which was contained in OSHA inspection number 116215120, citation number 2, item number 1 and was affirmed as a final order on June 1, 2011, with respect to a workplace located at 275 North Queen Street, Shippensburg Pennsylvania 17257.    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

Feb 6, 2014

Abate by

Mar 14, 2014

Penalty

Initial $7,700 · Current $5,390 Reduced

General-duty citation text

29 CFR 1910.184(e)(1): Alloy steel sling(s) did not have permanently affixed durable identification stating size, grade, rated capacity, and reach:    (a) Floor Shake Out - Employees used the alloy chain sling with the 1 ton under hung chain hoist to lift castings weighing up to 300 pounds.  The alloy chain had excessive wear and stretched links and did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (b) Osborn Shake Out - An employee used the alloy chain sling with the #32 Gardner Denver Pneumatic chain hoist to lift castings weighing up to 300 pounds.  The alloy chain shackle was stretched out of round where to pin threads in and the hook was excessively worn and did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 13, 2013.    (c) Shipping Building, Large Grinding Area - An employee used the alloy chain sling with the 1/2 ton underhung chain hoist to lift castings weighing up to 300 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (d) Shipping Building, Shipping Department - An employee used the alloy chain sling with the 1 ton underhung pneumatic chain hoist to lift castings weighing up to 300 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (e) Whiting Pour Crane - Employees used the alloy chain sling below the hook of the 5 ton overhead electric crane to lift, move and pour ladles of hot metal weighing up to 3000 lbs. The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (f) Large Blast - Employees used the  alloy chain sling below the hook of the pneumatic underhung chain hoist at large shot blast machine to lift castings weighing as much as 400 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (g) Rumbler Room, Large Grinding Area -  An employee used the alloy chain sling below the hook of the Gardner Denver pneumatic 2200 lb underhung chain hoist at the large grind station to lift castings weighing as much as 80 pounds.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about August 7, 2013.    (h) Small Shot Blast Shaker - An employee used the alloy chain sling below the hook of the ARO pneumatic 1100 lb chain hoist #14 to lift castings weighing as much as 200 lbs.  The alloy chain sling did not have a permanently affixed durable identification stating size, grade and rated capacity, on or about December 11, 2013.       The Domestic Casting Company, LLC was previously cited for a violation of this occupational safety and health standard or its equivalent standard, which was contained in OSHA inspection number 116215120, citation number 1, item number 5 and was affirmed as a final order on June 1, 2011, with respect to a workplace located at 275 North Queen Street, Shippensburg Pennsylvania, 17257.    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

Feb 6, 2014

Penalty

Initial $10,780 · Current $7,546 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding was 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)    Magnet Belt System 1 - The magnetic belt conveyor system was not provided with a guard.  Employees were exposed to the in going nip points and caught in hazards where the belt runs over the troughing idlers, on or about October 22, 2013.    The Domestic Casting Company, LLC was previously cited for a violation of this occupational safety and health standard or its equivalent standard, which was contained in OSHA inspection number 113744577, citation number 2, item number 1 and was affirmed as a final order on July 2, 2012, with respect to a workplace located at 275 North Queen Street, Shippensburg, PA 17257.      No abatement certification or documentation required.

Issued

Feb 6, 2014

Abate by

Apr 15, 2014

Penalty

Initial $19,250 · Current $13,475 Reduced

General-duty citation text

29 CFR 1910.219(d)(1): Pulley(s) with part(s) seven feet or less from the floor or work platform were not guarded in accordance with the requirements specified in 29 CFR 1910.219(m) and (o):    (a) Tower - The pulleys for electric motor and gear box of the wet sand elevator did not have guards installed, employees were exposed to the in going nip points and a caught in hazard, on or about October 22, 2013.    Domestic Casting LLC, was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 818141, citation number 2, item number 2a and was affirmed as a final order on July 30, 2013, with respect to a workplace located at 275 North Queen Street, Shippensburg Pennsylvania.    Domestic Casting LLC, was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number116215120, citation number2, item number 4 and was affirmed as a final order on June 1, 2011, with respect to a workplace located at 275 North Queen Street, Shippensburg, Pennsylvania.    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

Feb 6, 2014

Abate by

Apr 15, 2014

Penalty

Initial $26,950 · Current $18,060 Reduced

General-duty citation text

29 CFR 1910.219(f)(3): Sprocket wheels and chains which were 7 feet or less above floors or platforms were not enclosed:    (a) Tower - The chain and sprocket drive system for the rotary screen was 2 feet above the floor and was not guarded, exposing employees performing maintenance and housekeeping tasks in the tower to amputation hazards from ingoing nip points, on or about October 22, 2013.    (b) Tower - The chain and sprocket drive system for the dry sand elevator was 2 feet above the floor and was not guarded exposing employees performing maintenance and housekeeping tasks in the tower to amputation hazards from ingoing nip points, on or about October 22, 2013.    Domestic Casting, LLC was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 818141, citation number 2, item number 3 and was affirmed as a final order on July 30, 2013, with respect to a workplace located at 275 North Queen Street, Shippensburg Pennsylvania.    Domestic Casting, LLC was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 116215120, citation number 1, item number 7 and was affirmed as a final order on June 1, 2011, with respect to a workplace located at 275 North Queen Street, Shippensburg Pennsylvania.    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

Feb 6, 2014

Penalty

Initial $7,700 · Current $5,390 Reduced

General-duty citation text

29 CFR 1910.303(b) (7) (i): Unused openings in electrical boxes or housings were not effectively closed provide substantially equivalent protection to the wall of the equipment:    (a) Shipping Building, Between the Heat Treating Ovens - A three inch hole was not covered on the west side of the  220 volt disconnect switch box mounted to the column between the heat treating ovens.  Employees passed next to the column throughout the day to cycle castings through the ovens and were exposed to the live 220 volt buss inside the box, on or about August 7, 2013.       (b) Osborn Pour Area - The pendant housing for the crane had an unused opening that was not closed.  Employees held the pendant to operate the crane and were exposed to the live 110 volt current inside the pendant, on or about August 13, 2013.     The Domestic Casting Company, LLC was previously cited for a violation of this occupational safety and health standard or its equivalent standard, which was contained in OSHA inspection number 116215120, citation number 1, item number 8 and was affirmed as a final order on June 1, 2011, with respect to a workplace located at 275 North Queen Street, Shippensburg, Pennsylvania 17257.    No abatement certification or documentation required.

Issued

Feb 6, 2014

Penalty

Initial $7,700 · Current $5,390 Reduced

General-duty citation text

29 CFR 1910.305(b)(2): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:    (a) Shipping Building Near the Scale - The breaker box contained three 110 volt receptacle branch circuit breakers and one 220 volt breaker for the branch circuit used to supply power to the hearing van. There was no cover provided for the breaker box, employees were exposed to the hazard of electric shock / electrocution due to contact with live 220 Volt current on or about August 6, 2013.    Domestic Casting Company, LLC was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 818141, citation number 1, item number 6 and was affirmed as a final order on July 30 2013, with respect to a workplace located at 275 North Queen Street, Shippensburg, PA 17257.     No abatement certification or documentation required.

Issued

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.23(e)(2): Stair rails did not consist of a top rail, intermediate rail and/or posts, with the vertical height not more than 34 inches (86.36 cm) nor less than 30 inches (76.2 cm) from upper surface of top rail to surface of tread in line with face of riser at forward edge of tread:  (a) Tower - The stair rails did not have an intermediate rail.  Employees used the stairs from the roof of the foundry to the tower to perform maintenance, on or about October 22, 2013.  (b) Foundry - The stairs from the mixer area to the pour level did not have an intermediate rail.  Employees used the stairs to travel on and off of the pour deck, on or about October 22, 2013.  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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There existed damaged parts that could have adversely affected the safe operation or mechanical strength of electrical  equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating:  (a) Mixer - Live 115 VAC conductors ran through a metal conduit with a broken coupling, The wires were chafing against the sharp metal edges of the broken coupling and the edge of the conduit.  Employees were exposed to the possibility of electrical shock or fire hazard on or about October 22, 2013.  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

Feb 6, 2014

Abate by

Mar 5, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(f)(2): Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, was not legibly marked to indicate its purpose, nor located and arranged so the purpose was evident:  (a) Shipping Building Near The Scale - The breaker box contained three 110 volt receptacle branch circuit breakers and one 220 volt breaker for the branch circuit used to provide power to the hearing van. The purpose of each breaker was not identified on or about August 6, 2013.  (b) Core Room Across From The Office - The breaker box contained seven 110 volt branch circuit breakers.  The purpose of each breaker was not identified on or about August 13, 2013.    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.