OSHA Inspection: K CASTINGS, INC.

Issued

Feb 10, 2014

Abate by

May 9, 2014

Penalty

Initial $2,400 · Current $1,680 Reduced

Hazardous substances 0730

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of copper listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 0.10 milligrams per cubic meter of air (mg/m3):     a)  In the Facility, on or about December 11, 2013 - An employee designated as a Cutoff Saw Operator/Grinder was exposed to copper at a time weighted average exposure of 0.25 mg/m3.  This level is 2.5 times the permissible exposure limit of 0.1 mg/m3 as a time weighted average concentration.  Sampling was performed by an OSHA compliance officer on 12/11/13 for 458 minutes and zero exposure was assumed for the unsampled portion of the shift.    b)  In the Facility, on or about December 11, 2013 - An employee designated as a Grinder was exposed to copper at a time weighted average exposure of 0.35 mg/m3.  This level is 3.5 times the permissible exposure limit of 0.1 mg/m3 as a time weighted average concentration.  Sampling was performed by an OSHA compliance officer on 12/11/13 for 452 minutes and zero exposure was assumed for the unsampled portion of the shift.    c)  In the Facility, on or about December 11, 2013 - An employee designated as a Melter was exposed to copper at a time weighted average exposure of 0.11 mg/m3.  This level is 1.1 times the permissible exposure limit of 0.1 mg/m3 as a time weighted average concentration.  Sampling was performed by an OSHA compliance officer on 12/11/13 for 448 minutes and zero exposure was assumed for the unsampled portion of the shift.    d)  In the Facility, on or about December 11, 2013 - An employee designated as a Molder was exposed to copper at a time weighted average exposure of 0.33 mg/m3.  This level is 3.3 times the permissible exposure limit of 0.1 mg/m3 as a time weighted average concentration.  Sampling was performed by an OSHA compliance officer on 12/11/13 for 400 minutes and zero exposure was assumed for the unsampled portion of the shift.    e)  In the Facility, on or about December 11, 2013 - An employee designated as a Molder was exposed to copper at a time weighted average exposure of 0.36 mg/m3.   This level is 3.6 times the permissible exposure limit of 0.1 mg/m3 as a time weighted average concentration.  Sampling was performed by an OSHA compliance officer on 12/11/13 for 450 minutes and zero exposure was assumed for the unsampled portion of the shift.

Issued

Feb 10, 2014

Abate by

May 9, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0730

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)  In the Facility, on or about December 11, 2013 - The employer did not implement feasible engineering controls to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d).  Employees were exposed to copper above the permissible exposure level.  (See descriptions of employee exposures in Citation 1, Item 1a, Instances  a-e).  Feasible engineering controls would include but not be limited to:  1.  Maintain the existing mechanical ventilation system in use at the facility;  and  2.  Operate the ventilation system throughout the work shift rather than only when the metal is melting.

Issued

Feb 10, 2014

Abate by

Mar 28, 2014

Penalty

Initial $1,600 · Current $1,040 Reduced

Hazardous substances 0730

General-duty citation text

29 CFR 1910.134(c): The employer did not develop and implement a written respiratory protection program with required worksite-specific procedures and elements for required respirator use:    a)  In the facility, on or about December 3, 2013 - The employer did not develop and implement a written respirator program with worksite-specific procedures when employees are required to wear respirators in the workplace.

Issued

Feb 10, 2014

Abate by

Mar 28, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0730

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer did not identify and evaluate the respiratory hazard(s) in the workplace; including a reasonable estimate of employee exposures to respiratory hazards and identification of the contaminants chemical state and physical form:   a)  In the facility, on or about December 3, 2013 - The employer did not identify and evaluate the respiratory hazards in the workplace including but not limited to employee's exposure to copper.

Issued

Feb 10, 2014

Abate by

Mar 28, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0730

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:    a)  In the facility, on or about December 3, 2013 - The employer did not provide a medical evaluation to employees, before the employee is required to wear a respirator in the workplace.  Employees are required to wear a respirator in the workplace during foundry working operations including but not limited to melting, pouring, molding, grinding and core making operations.

Issued

Feb 10, 2014

Abate by

Mar 28, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0730

General-duty citation text

29 CFR 1910.134(f)(1): The employer did not ensure that employee(s) required to use a tight-fitting facepiece respirator passed the appropriate qualitative fit test (QLFT) or quantitative fit test (QNFT):   a)  In the facility, on or about December 3, 2013 - The employer did not ensure that employees were provided a fit test when the employee is required to wear a respirator in the workplace.  Employees are required to wear a respirator in the workplace during foundry working operations including but not limited to melting, pouring, molding, grinding and core making operations.

Issued

Feb 10, 2014

Abate by

Mar 28, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0730

General-duty citation text

29 CFR 1910.134(k)(1): The employer did not provide effective training to employees who are required to use respirators in the workplace:   a)  In the facility, on or about December 3, 2013 - The employer did not provide training to employees who are required to use respirators in the workplace.  Employees are required to wear a respirator in the workplace during foundry working operations including but not limited to melting, pouring, molding, grinding and core making operations.

Issued

Feb 10, 2014

Abate by

Apr 15, 2014

Penalty

Initial $1,600 · Current $1,120 Reduced

Hazardous substances 1592

General-duty citation text

29 CFR 1910.1025(j)(2)(i):  The employer shall make available biological monitoring in the form of blood sampling and analysis for lead and zinc protoporphyrin levels to each employee covered under paragraph (j)(1)(i) of this section:    a)  In the facility, on or about December 3, 2013 - The employer did not provide biological monitoring in the form of blood sampling and analysis for lead and zinc protoporphyrin to each employee who was exposed to lead above the action level.

Issued

Feb 10, 2014

Abate by

Apr 15, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 1592

General-duty citation text

29 CFR 1910.1025(j)(3)(i)(B): Medical examinations and consultations for lead were not performed prior to assignment for each employee being assigned for the first time to an area in which airborne concentrations of lead are at or above the action level:      a)  In the facility, on or about December 3, 2013 - The employer did not provide a medical examination and consultation for each employee who was exposed to lead above the action level.

Issued

Feb 10, 2014

Abate by

Apr 15, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 1592

General-duty citation text

29 CFR 1910.1025(l)(1)(i): Employee(s) working in an area where there is potential exposure to airborne lead at any level were not informed of the content of Appendices A and B of 29 CFR 1910.1025:      a)  In the facility, on or about December 3, 2013 - The employer did not inform employees of the contents of Appendices A and B of the lead standard when the employees were exposed to lead above the action level.