OSHA Inspection: WISCONSIN ALUMINUM FOUNDRY CO., INC.

Issued

Jul 15, 2014

Abate by

Jan 2, 2015

Penalty

Initial $4,250 · Current $2,975 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)  In Knockout located adjacent to small brass area, a Knockout employee was exposed to noise at 1111% (noise dose) of the allowable noise dose of 100% during a sample period of 392 minutes during one shift on 03/27/2014.    Applicable administrative or engineering controls may include, but are not limited to the following:      1)  Conduct thorough noise studies in the Knockout department to verify noise sources, source noise frequencies, reflective surfaces and employee operations/positions for most effective engineering controls.        2)  Enclose the rattler machine so that when a part is being processed the Knockout operator is not exposed to its unimpeded noise.      3)  Move the rattler machine so that the noise produced by the machine is not directed into any employees' work station, including the Knockout employee's.

Issued

Jul 15, 2014

Abate by

Feb 6, 2015

Penalty

Initial $2,550 · Current $1,275 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(e)(1)(i):  For any employees exposed to lead above the permissible exposure limit for more than 30 days per year the employer did not implement engineering and work practice controls (including administrative controls) to reduce and maintain employee exposure to lead:    a)  In the brass finishing area, a Brass Finishing employee was exposed to airborne lead at a level of 133 ug/m3 as an 8-hour time weighted average (TWA) on 05/06/2014, approximately 2.6 times the permissible exposure limit of 50 ug/m3.  This exposure was determined by air sampling conducted over 460 minutes during one shift, with zero exposure being assumed for the unsampled 20 minutes of an 8-hour work shift.    Controls in these circumstances may include, but are not limited to, the following:    1)  Installation of mechanical local exhaust ventilation to capture and remove lead dust before it reaches the employees' breathing zones.    2)  Installation of tempered fresh air islands, where clean air is introduced to the employees' breathing zones.    3)  Conduct air monitoring surveys and use quality assurance methods to identify which alloys, castings and/or processes produce the highest air contaminant levels and to verify the effectiveness of controls.    4)  Elimination of personal cooling fans which can entrain contaminated air into the employees' breathing zones.    5)  Retain the services of professionals in the field of foundry ventilation to design and help control air moving system to gain the maximum effect.

Issued

Jul 15, 2014

Abate by

Sep 3, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(e)(3)(i): The employer did not establish and implement a written compliance program to reduce exposures to or below the permissible exposure limit, solely by means of engineering and work practice controls:  a)  On or about 05/06/2014, the employer did not establish and implement a written compliance program to reduce exposures to lead to or below the permissible exposure limit, solely by means of engineering and work practice controls, when a Brass Finishing employee was exposed to airborne lead at a level of 133 ug/m3 as an 8-hour time weighted average (TWA).

Issued

Jul 15, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(j)(2)(i): Required biological monitoring in the form of blood sampling and analysis for lead and zinc protoporphyrin (ZPP) levels were not provided to each employee covered under 29 CFR 1910.1025 (j)(1)(i):  a)  On or about 05/06/2014, the employer did not provide required biological monitoring in the form of blood sample analysis for zinc protoporphyrin (ZPP) levels when a Brass Finishing employee was exposed to airborne lead at a level of 133 ug/m3 as an 8-hour time weighted average (TWA).