OSHA Inspection: ACTIVE BRASS FOUNDRY, INC.

Issued

Jul 14, 2015

Abate by

Aug 16, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(l)(1)(iv): A training program was not repeated at least annually for each employee subject to lead exposure at or above the action level, or for whom the possibility of skin or eye irritation existed:    a) Active Brass Foundry - Molding Dept. - On or about April 15, 2015, A Metal Melter operating the blast furnace to melt red brass, was exposed to lead at an 8 hour time weighted average (TWA) concentration of 78 micrograms per cubic meter of air (ug/m3), which is 1.57 times the permissible exposure limit (PEL) of 50 ug/m3, and the employer did not provide annual lead training.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Oct 14, 2015

Penalty

Initial $2,040 · Current $807 Reduced

Hazardous substances 81108111

General-duty citation text

29 CFR 1910.95(b)(1): When employees were subjected to sound exceeding those listed in Table G-16, feasible engineering controls were not utilized:    a)  Active Brass Foundry - A Metal Melter employee was exposed to continuous noise at 147.1% of the permissible exposure limit of 90 dBA or an eight-hour time weighted average of 92.7 dBA.  This exposure was observed over a 453 minute sampling period a zero exposure was assumed for the 27 minutes not sampled.  The employer did not utilize feasible engineering controls to reduce sound levels for those employees exposed over the permissible exposure limit of 90 dBA, on or about March 18, 2015.    b)  Active Brass Foundry - A Metal Melter employee was exposed to continuous noise at 174.2% of the permissible exposure limit of 90 dBA or an eight-hour time weighted average of 94.0 dBA.  This exposure was observed over a 452 minute sampling period, a zero exposure was assumed for the 28 minutes not sampled.  The employer did not utilize feasible engineering controls to reduce sound levels for those employees exposed over the permissible exposure limit of 90 dBA, on or about March 18, 2015.    Feasible abatement methods includes, but is not limited to:  1.  Repair broken weld where shakeout filter screen attaches to metal angle by main vibrating motor for second leg of vibrating conveyor.    2.  Repair broken shaker coil attachment bolt on secondary conveyor directly adjacent to where the Metal Melter picks the castings up off the conveyor.     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, photograph or video evidence of abatement or other written records.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $2,800 · Current $1,106 Reduced

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices were not affixed to each energy isolating device by authorized employees:    a)  Active Brass Foundry - On or about March 11, 2015, employees engaged in repairing the Sinto mold machine track conveyor did not affix a personal lockout or tagout device to a group lockout device prior to working on the machine or equipment. The employees were working in between the conveyor sections which exposed them to amputation hazards.      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, photograph or video evidence of abatement or other written records.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(6)(ii):  The employer shall certify that the periodic inspections have been performed.  The certification shall identify the machine or equipment on which the energy control procedure was being utilized, the date of the inspection, the employees included in the inspection, and the person performing the inspection.  a)  Active Brass Foundry - On or about March 11, 2015, the employer did not certify the periodic inspection of the energy control procedure by documenting the date of the inspection, the employees included in the inspection, and the person performing the inspection.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not provide adequate training to ensure that the purpose and function of the energy control program was understood by employees:  a)  Active Brass Foundry - On or about March 11, 2015, employees engaged in repairing the Sinto mold machine track conveyor did not utilize lockout/tagout devices to prevent unexpected start up of the conveyor system.  b)  Active Brass Foundry - On or about March 11, 2015 an employees engaged in repairing the Sinto mold machine track conveyor and exposed to injury from unexpected start-up was not authorized employees under the employers lockout tagout program.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Aug 15, 2015

Penalty

Initial $2,040 · Current $807 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s):    a)  Active Brass Foundry - An employee operating the Redford shell core machine was exposed to crush and/or amputation hazards from an unguarded mold press area of the machine, on or about March 18, 2015.    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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $1,020 · Current $404 Reduced

General-duty citation text

29 CFR 1910.242(b): Compressed air used for cleaning purposes was not reduced to less than 30 p.s.i.:    a) Active Brass Foundry - On or about April 15, 2015, employees were exposed to flying sand particles and compressed air hazards from air nozzles used for cleaning sand off of machinery where the dead end pressure exceeded 30 p.s.i.      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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Aug 15, 2015

Penalty

Initial $2,040 · Current $807 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(c)(1): The employer did not ensure that no employee was exposed to an airborne concentration of lead in excess of fifty micrograms per cubic meter of air averaged over an eight-hour period:     a) Active Brass Foundry - Molding Dept. - A Metal Melter operating the blast furnace to melt red brass, was exposed to lead at an 8 hour time weighted average (TWA) concentration of 78 micrograms per cubic meter of air (ug/m3), which is 1.57 times the permissible exposure limit (PEL) of 50 ug/m3.  This exposure occurred over a 425 minute sampling period, which occurred on or about April 15, 2015.  A zero exposure was assumed for the 55 minutes not sampled.    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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 0731152015911620C141

General-duty citation text

29 CFR 1910.134(f)(2): Employee(s) using a tight-fitting facepiece respirator were not annually fit tested:    a)  Active Brass Foundry - On or about February 11, 2015, employees melting aluminum and brass metal were required to wear a half-face disposable respirator and the employer did not annually ensure that employee(s) using a tight-fitting facepiece respirator pass an appropriate qualitative fit test or quantitative fit test.    No abatement certification or documentation required.  Corrected during inspection.

Issued

Jul 13, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 0731152015911620C141

General-duty citation text

29 CFR 1910.134(k)(5): Respiratory protection retraining was not conducted annually:    a)  Active Brass Foundry - On or about February 11, 2015, employees melting aluminum and brass metal were required to wear a half-face disposable respirator and the employer did not provide annual training to ensure that employee(s) required to use respirator(s) could demonstrate knowledge of the requirements of this section.  No abatement certification or documentation required.  Corrected during inspection.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 0731152015911620C141

General-duty citation text

29 CFR 1910.134(m)(2)(i)(C): The employer did not establish a record of the qualitative and quantitative fit tests administered to an employee which included the specific make, model, style and size of respirator tested:  a)  Active Brass Foundry - For employees who were required to wear respiratory protection, the employer did not establish a fit test record that included the specific make, model, style and size of the respirator being fit tested, on or about February 11, 2015.   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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Aug 15, 2015

Penalty

Initial $2,040 · Current $807 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(i)(3)(i): Employee(s) exposed to lead in excess of the permissible exposure limit (PEL), without regard to the use of respirators, were not required to shower at the end of the work shift:      a) Active Brass Foundry - Molding Dept. - On or about April 15, 2015, a Metal Melter operating the blast furnace to melt red brass, was exposed to lead at an 8 hour time weighted average (TWA) concentration of 78 micrograms per cubic meter of air (ug/m3), which is 1.57 times the permissible exposure limit (PEL) of 50 ug/m3, and the employer did not ensure that employees shower at the end of their shift.    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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.141(d)(3)(v):  Employees who are required to use showers were not provided with individual clean towels:  a) Active Brass Foundry - On or about June 9, 2015, Metal Melters who were required under the lead and cadmium standards to shower at the end of their shift were not provided individual clean towels by the employer.   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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $2,040 · Current $807 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(g)(2)(v): Contaminated protective clothing to be cleaned, laundered, or disposed of, was not placed in a closed container to prevent dispersion of lead outside the container:      a) Active Brass Foundry - Molding Dept. - The employer is required to launder protective clothing worn by Metal Melters and the employer did not place the contaminated clothing in closed containers to prevent the dispersion of lead, on about June 9, 2015.    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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(g)(2)(vii): Containers of contaminated protective clothing and equipment required by 29 CFR 1910.1025 (g)(2)(v) were not labeled as follows: CAUTION: CLOTHING CONTAMINATED WITH LEAD. DO NOT REMOVE DUST BY BLOWING OR SHAKING. DISPOSE OF LEAD CONTAMINATED WASH WATER IN ACCORDANCE WITH APPLICABLE LOCAL, STATE OR FEDERAL REGULATIONS:  a) Active Brass Foundry - Molding Dept. - The employer is required to launder protective clothing worn by Metal Melters and the employer did not label the contaminated clothing container with the lead caution wording as required by this paragraph, on about June 9, 2015.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(g)(2)(vi): Persons who clean or launder protective clothing or equipment were not informed, in writing, of the potentially harmful effects of exposure to lead:    a) Active Brass Foundry - Molding Dept. - The employer is required to launder protective clothing worn by employees in the Molding Department, and the contracted uniform cleaning company was not notified in writing of the potentially harmful effects of lead, on about June 9, 2015.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Jul 31, 2015

Penalty

Initial $0 · Current $0

Hazardous substances C141

General-duty citation text

29 CFR 1910.1027(i)(3)(v): The employer did not inform any person who launders or cleans protective clothing or equipment contaminated with cadmium of the potentially harmful effects of exposure to cadmium and that the clothing and equipment should be laundered or cleaned in a manner to effectively prevent the release of airborne cadmium in excess of the permissible exposure limit (PEL):    a) Active Brass Foundry - Molding Dept. - The employer is required to launder protective clothing worn by employees in the Molding Department, and the contracted uniform cleaning company was not notified in writing of the potentially harmful effects of cadmium, on about June 9, 2015.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Abate by

Aug 15, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(j)(2)(i)(A): The employer did not make available biological monitoring in the form of blood sampling and analysis for lead and zinc protoporphyrin levels at least every 6 months to each affected employee:  a) Active Brass Foundry - Molding Dept. - On or about April 15, 2015, a Metal Melter operating the blast furnace to melt red brass, was exposed to lead at an 8 hour time weighted average (TWA) concentration of 78 micrograms per cubic meter of air (ug/m3), which is 1.57 times the permissible exposure limit (PEL) of 50 ug/m3, and the employer did not make biological monitoring available at least every 6 months.  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 that employees and their representatives were informed of this abatement.

Issued

Jul 13, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.157(g)(2): The educational program to familiarize employees with the general principles of fire extinguisher use and the hazards involved with incipient stage fire fighting was not provided to all employees upon initial employment, and at least annually thereafter:  a) Active Brass Foundry - The employer provides fire extinguishers for employees who melt and pour molten metals, and the employer did not annually provide fire extinguisher training to ensure that employees are educated with the general principles of fire extinguisher use and the hazards involved with incipient stage fire fighting, on or about February 11, 2015.      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 that employees and their representatives were informed of this abatement.    ABATEMENT NOTE: By this date the employer must either correct the alleged violation or implement a Fire Safety Policy, as outlined in 29 CFR 1910.38(a) and (b) which included the evacuation requirement of 29 CFR 1910.157(b).