OSHA Inspection: SANCAST, INC. A SUBSIDIARY OF WABTEC

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $5,500 · Current $4,400 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.   a. Located on the Foundry Pangborn Barrel Blast Machine, model number 15 GN-4, there was a fixed metal ladder that was used by maintenance employees to gain access to and from the top of the Pangborn.  The fixed ladder had a vertical distance of 45 inches from the floor to the first rung, thereby exposing the employees to a fall hazard from the ladder.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $5,500 · Current $4,400 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    a.  Located on the Logan Overhead Trolley Conveyor System, there were employees that were required to operate the trolley system at a control station that was inside of the trolley's radius.  The operator was at risk of a struck-by hazard due to a runaway condition that would occur when a link on the drive chain would break, causing the declined part of the trolley system to move down the guiderails uncontrollably where the operator's station was located.      b.  Located on the Logan Overhead Trolley Conveyor System, there were employees that were required to operate the trolley system without an adequate maintenance program, thereby exposing the employees to a struck-by and/or caught-between hazard.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $4,400 · Current $3,520 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.    a.  Located at the pour deck, employees operated a 1 ton Budgit electrically motorized trolley chain hoist, model number BEHC-0116, in order to hoist and pour approximately 900 pound molten metal pots with use of a below-the-hook lifting device that did not have an identification plate or any other means to indicate the lifting device's lifting capacity, thereby exposing the employees to a struck-by and/or caught-between hazard.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $7,000 · Current $5,600 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.      a.  Located at the pour deck, employees operated two, 1 ton Budgit electrically motorized trolley chain hoist in order to hoist and pour up to approximately 900 pound molten metal ladles without conducting frequent inspections and periodic inspections with a certification record, thereby exposing the employees to struck-by, caught-between, electrical, and/or burn hazards.       b.  Located at the end of the pour deck, employees operated a 1 ton Budgit electrically motorized trolley chain hoist, model number, BEHC-0116 with a pendant control box that had been melted and was no longer constructed to prevent electrical shock of 110 volts.      c.  Located at the pour deck, employees operated a 1 ton Budgit electrically motorized trolley chain hoist, model number BEHC-0116, with a pendant control box that did not have any identification labels for the safe operation of the crane, thereby exposing the employees to a burn, struck-by, and/or caught-between hazard.    d.  Located at the pour deck, employees operated one ton Budgit electrically motorized trolley chain hoists, model number BEHC-0116, without any indication of the hoists capacity, thereby exposing the employees to a burn, struck-by, and/or caught-between hazard.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $5,500 · Current $4,400 Reduced

General-duty citation text

29 CFR 1910.27(c)(4): "Clearance in back of ladder." The distance from the centerline of rungs, cleats, or steps to the nearest permanent object in back of the ladder shall be not less than 7 inches, except that when unavoidable obstructions are encountered, minimum clearances as shown in figure D-3 shall be provided. Minimum Ladder Clearances FIGURE D-3. - Clearance for Unavoidable Obstruction at Rear of Fixed Ladder  a. Located on the south side of the raw material staging area, there was a fixed metal ladder that allowed employees access to and from a walkway along the raw material bins.  There was a piece of channel attached as a support brace for the walkway which did not allow for the seven inches of clearance for employees to safely ascend or descend the ladder, thereby exposing the employees to a fall hazard of 5 feet, 7 inches.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $7,000 · Current $5,600 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii): The procedures shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, the following:     29 CFR 1910.147(c)(4)(ii)(B): Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy;     a. Located on the Foundry Pangborn Barrel Blast Machine's control panel, there were lockout/tagout procedures posted that were not complete.  The procedures did not include the control of all the hazardous energy that presented a hazard to employees in the shutting down of equipment, verification of de-energized sources, isolation/securing of the Pangborn's chute, and procedures for safely restoring equipment into service.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $5,500 · Current $4,400 Reduced

General-duty citation text

29 CFR 1910.179(j)(2): Frequent inspection. The following items shall be inspected for defects at intervals as defined in paragraph (j)(1)(ii) of this section or as specifically indicated, including observation during operation for any defects which might appear between regular inspections. All deficiencies such as listed shall be carefully examined and determination made as to whether they constitute a safety hazard:   a.  Located in the foundry at Sancast, there was a five ton Shepard Niles overhead crane, model number 68768, that employees used to hoist material and equipment that was not inspected daily, thereby exposing the employees to struck-by and/or caught-between hazards.  b.  Located in the foundry at Sancast, there was a three ton overhead crane that employees used to hoist material and equipment that was not inspected daily, thereby exposing the employees to struck-by and/or caught-between hazards.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(m)(1): Running ropes. A thorough inspection of all ropes shall be made at least once a month and a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes which were inspected shall be kept on file where readily available to appointed personnel. Any deterioration, resulting in appreciable loss of original strength, shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following:  29 CFR 1910.179(m)(1)(ii): A number of broken outside wires and the degree of distribution or concentration of such broken wires.  a.  Located at the charge material area, employees operated a 5 ton Shepard Niles overhead crane, model number 68768, with a magnet used to hoist raw material. There were multiple broken outside wires throughout one section of reeving on a running sheave, thereby exposing employees to a struck-by and/or caught-between hazard.

Issued

May 2, 2014

Penalty

Initial $5,500 · Current $4,400 Reduced

General-duty citation text

29 CFR 1910.179(n)(4)(i): At the beginning of each operator's shift, the upper limit switch of each hoist shall be tried out under no load. Extreme care shall be exercised; the block shall be "inched" into the limit or run in at slow speed. If the switch does not operate properly, the appointed person shall be immediately notified.  a.   Located at the melt deck, on or about November 5, 2013, employees were required to hoist charge buckets in order to load furnaces with a 3 ton overhead crane that had a limit switch that was bent.  The limit switch did not prevent the crane's block from coming into contact with the hoist drum, thereby exposing the employees to a struck-by and/or caught-between hazard.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $5,500 · Current $4,400 Reduced

General-duty citation text

29 CFR 1910.212(a)(4): Barrels, containers, and drums. Revolving drums, barrels, and containers shall be guarded by an enclosure which is interlocked with the drive mechanism, so that the barrel, drum, or container cannot revolve unless the guard enclosure is in place.        a. Located on the back of the Foundry Pangborn Barrel Blast Machine, employees were required to remove casting parts from the back of the Pangborn by opening two hinged doors by hand.  The doors were not interlocked with the drive mechanism, thereby exposing the employees to the ingoing nip point of the revolving barrel of the Pangborn.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $5,500 · Current $4,400 Reduced

General-duty citation text

29 CFR 1910.303(g)(1): Space about electric equipment. Sufficient access and working space shall be provided and maintained about all electric equipment to permit ready and safe operation and maintenance of such equipment.   a.  Located along the wall behind the melt deck, there were three 480 volt disconnects that were used in part to supply electrical power to the furnace and other equipment on the melt deck.  The electrical disconnects were blocked by 30 gallon cardboard drums and a Lincoln Electric stick welder, which did not allow for sufficient access to the electrical disconnects if an emergency occurred with the equipment and electrical power had to be immediately removed.

Issued

May 2, 2014

Penalty

Initial $5,500 · Current $4,400 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in cabinets, boxes, and fittings shall be effectively closed.  a.  Located on the Foundry Pangborn Barrel Blast Machine, model number 15 GN-4, there was a 3-phase, 480volt disconnect box that employees used to shut power on and off on the Pangborn that had two knockouts that were not closed, thereby exposing the employees to an arc flash/arc blast hazard.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $38,500 · Current $30,800 Reduced

General-duty citation text

29 CFR 1910.23(c)(1): Every open-sided floor or platform 4 feet or more above adjacent floor or ground level shall be guarded by a standard railing (or the equivalent as specified in paragraph (e)(3) of this section) on all open sides except where there is entrance to a ramp, stairway, or fixed ladder. The railing shall be provided with a toeboard wherever, beneath the open sides,     a.  Located at the charge material staging area, employees were required to operate a 5 ton overhead crane from a  wired pendant control box in order to hoist the raw material with a magnet while being exposed to a fall hazard of a maximum height of 7 feet, 2 inches from the top of a wooden timbered platform to the bottom of the raw material bin.       b.  Located at the charge material staging area, there was an approximately 18 inch wide walkway that was perpendicular to another walkway that allowed for employees to gain access to a wooden timbered platform that had a approximately 6 foot section of guardrail missing, thereby exposing the employees to a fall hazard of 8 feet, 4 inches.          Sancast was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.23(c)(1) which was contained in OSHA inspection number 910120, citation number 1, item number 1 and was affirmed as a final order on September 25, 2013 with respect to a workplace located at 535 Clow Lane Coshocton, Ohio 43812.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $27,500 · Current $22,000 Reduced

General-duty citation text

29 CFR 1910.219(d)(1): Guarding. Pulleys, any parts of which are seven (7) feet or less from the floor or working platform, shall be guarded in accordance with the standards specified in paragraphs (m) and (o) of this section. Pulleys serving as balance wheels (e.g., punch presses) on which the point of contact between belt and pulley is more than six feet six inches (6 ft. 6 in.) from the floor or platform may be guarded with a disk covering the spokes.  a.  Located on the foundry Pangborn barrel blast machine 15 GN-4, there was a shaker table that had a 480 volt electric drive motor with a double pulley that had 1/2 inch drive belts that went to a 14 inch flywheel that did not have an adequate guard, thereby exposing the employees to the ingoing nip point.    Sancast was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.219(d)(1) which was contained in OSHA inspection number 751141, citation number 1, item number 1a and was affirmed as a final order on March 16, 2013, with respect to a workplace located at 525 Clow lane Coshocton, Ohio 43812.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $27,500 · Current $22,000 Reduced

General-duty citation text

29 CFR 1910.219(f)(3): Sprockets and chains. All sprocket wheels and chains shall be enclosed unless they are more than seven (7) feet above the floor or platform. Where the drive extends over other machine or working areas, protection against falling shall be provided. This subparagraph does not apply to manually operated sprockets.  a.  Located on the Foundry Pangborn Barrel Blast Machine 15 GN-4, there was a chain and sprocket that was used in part to rotate the Pangborn's barrel in order to sandblast casting parts.  The chain and sprocket's ingoing nip point was at a height of 81-1/2 inches from the walking surface, which exposed the employees to ingoing nip point hazards.    Sancast was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.219(f)(3) which was contained in OSHA inspection number 751141, citation number 1, item number 2 and was affirmed as a final order on March 16, 2013, with respect to a workplace located at 525 Clow lane Coshocton, Ohio 43812.

Issued

May 2, 2014

Abate by

May 29, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(6): Each exit sign must be illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and be distinctive in color. Self-luminous or electroluminescent signs that have a minimum luminance surface value of at least .06 footlamberts (0.21 cd/m2) are permitted.  a.  Located near the raw material delivery rolling steel door, the employer failed to ensure that an exit sign was illuminated for employees to exit in case of an emergency.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(l)(4)(iii): An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.    a.  Located throughout the facility, employees operated forklifts for periods longer than 3 years without an evaluation of the operator's performance.

Issued

May 2, 2014

Abate by

Jun 16, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(1)(ii): Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and "periodic" with respective intervals between inspections as defined below:    29 CFR 1910.179(j)(1)(ii)(b): Periodic inspection - 1 to 12-month intervals.    a.  Located in the foundry at Sancast, there was a five ton Shepard Niles overhead crane, model number 68768, that employees used to hoist material and equipment which did not have periodic inspections documented.    b.  Located in the foundry at Sancast, there was a three ton overhead crane that employees used to hoist material and equipment which did not have periodic inspections documented.