OSHA Inspection: FALCON CASTINGS, INC.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,000 · Current $500 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: Note: Toeboards are only required when persons can pass, there is moving equipment or there is equipment with which falling materials could create a hazard.    (a) Foundry #1, above Pangborn shot blaster, on or about March 29, 2016, employees troubleshooting operations were not provided fall protection when exposed to a 7 foot fall hazard to concrete floor below.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $1,200 · Current $500 Reduced

General-duty citation text

29 CFR 1910.23(d)(1)(iii): Stairway(s) less than 44 inches wide having both sides open, did not have one stair railing on each side:    (a) Shakeout Deck, on or about and at times preceding to January 14, 2016, the 5-step stairway was not provided with a mid-rail.     (b) Sand Reclamation Area, on or about and at times preceding to March 30, 2016, the 4-step stairway was not provided with standard railings on both sides.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

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:  (a) Sand Reclamation Area, on or about and at times preceding to March 30, 2016, the 4-step stairway was not provided with uniform tread height.

Issued

Jul 7, 2016

Abate by

Aug 23, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 8111

General-duty citation text

29 CFR 1910.95(c)(1): The employer did not administer a continuing, effective hearing conservation program as described in 29 CFR 1910.9(c) through (o) whenever employee noise exposures equal or exceed an 8-hour time-weighted average sound level of 85 decibels measured on the A scale, or equivalently a dose of fifty percent:    (a) In the Shot Blasting Area, on or about March 30, 2016, and at times prior to, the employer did not institute an effective hearing conservation program for a shot blasting machine operator who was exposed to an 8-hour time-weighted average sound level of 90.8 dBA during the 440 minute sampling period, which is 2.24 times the Action Level of 85 dBA, resulting in a progressive hearing loss hazard.    (b) In the Welding Area, on or about March 30, 2016, and at times prior to, the employer did not institute an effective hearing conservation program for a welder who was exposed to an 8-hour time-weighted average sound level of 88.0 dBA during the 360 minute sampling period, which is 1.53 times the Action Level of 85 dBA, resulting in a progressive hearing loss hazard.    (c) In the Sand Reclamation Area, on or about March 30, 2016, and at times prior to, the employer did not institute an effective hearing conservation program for the operator who was exposed to an 8-hour time-weighted average sound level of 87.0 dBA during the 420 minute sampling period, which is 1.32 times the Action Level of 85 dBA, resulting in a progressive hearing loss hazard.    (d) In the Cast Cleaning Area, on or about March 30, 2016, and at times prior to, the employer did not institute an effective hearing conservation program for a cast cleaner who was exposed to an 8-hour time-weighted average sound level of 95.8 dBA during the 430 minute sampling period, which is 4.51 times the Action Level of 85 dBA, resulting in a progressive hearing loss hazard.    (e) In the Cast Cleaning Booth, on or about March 30, 2016, and at times prior to, the employer did not institute an effective hearing conservation program for arc gouger who was exposed to an 8-hour time-weighted average sound level of 89.7 dBA during the 438 minute sampling period, which is 1.93 times the Action Level of 85 dBA, resulting in a progressive hearing loss hazard

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 8110

General-duty citation text

29 CFR 1910.95(i)(2)(i): The employer did not ensure that hearing protectors are worn by an employee who is required by 29 CFR 1910.95(b)(1) to wear personal protective equipment:  (a) In the Cast Cleaning Area, on or about March 30, 2016, and at times prior to, the employer did not require employee to utilize hearing protection who was exposed to an 8-hour time-weighted average sound level of 95.0 dBA during the 430 minute sampling period, which is 2.02 times the Permissible Exposure Level (PEL) of 90 dBA.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

General-duty citation text

29 CFR 1910.132(a): Protective equipment was not maintained in a sanitary and reliable condition:     (a) Foundry Facilities #1 & #2, on or about and at times preceding March 29, 2016, hand protection available for use was in disrepair with holes, rips, and tears when used during grinding operations, metal pouring operations, welding operations, mold curing operations and cast cleaning operations.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $1,600 · Current $500 Reduced

General-duty citation text

29 CFR 1910.132(h)(1): Personal protective equipment (PPE), was not provided by the employer at no cost to employees.    (a) Foundry Facilities #1 & #2, on or about and at times preceding March 29, 2016, personal protective equipment including gloves and safety glasses, including prescription safety glasses, were not provided free of charge for employee required use during arc gouging, welding, grinding, shot blasting, lifting and moving metal castings, and metal pouring operations.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,000 · Current $900 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B): The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy:    (a) Foundry #1, on or about and at times preceding to March 30, 2016, specific procedures had not been developed for equipment including but not limited to: troubleshooting Pangborn shot blaster to control hazardous energy.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

General-duty citation text

29 CFR 1910.178(l)(1)(i): The employer did not ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l):    (a) Foundry Facility, on or about and at times preceding to January 14, 2016, employees who had not been trained were operating Hyster serial #RMK 825978 forklift used to transport molds and other products throughout the facilities.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(m)(3): Unauthorized personnel were permitted to ride on industrial truck(s):  (a) Foundry Facility, on or about and at times preceding to January 14, 2016, operators transported personnel on the forklift tines.

Issued

Jul 7, 2016

Penalty

Initial $1,360 · Current $500 Reduced

Hazardous substances 15919010

General-duty citation text

29 CFR 1910.215(b)(9): The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch:     (a) Foundry #1, on or about and at times preceding to March 30, 2016, tongue guards on pedestal grinders measured 2 inch opening to abrasive wheel periphery.

Issued

Jul 7, 2016

Penalty

Initial $1,200 · Current $500 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) Foundry Facility, on or about and at times preceding to January 14, 2016, compressed air used for cleaning off molds was measured at 65 psi.

Issued

Jul 7, 2016

Penalty

Initial $1,600 · Current $500 Reduced

General-duty citation text

29 CFR 1910.243(c)(1): Abrasive wheel(s) were used on portable grinder(s) which were not provided with safety guard(s) meeting the requirements specified in 29 CFR 1910.243(c)(1) through (c)(4).    (a) Foundry Facility, on or about and at times preceding to March 31, 2016, DeWalt serial #541292 portable 4 inch abrasive wheel hand grinder was not equipped with an abrasive wheel safety guard.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,000 · Current $500 Reduced

General-duty citation text

29 CFR 1910.254(d)(9)(iii): Cables with damaged insulation or exposed bare conductors were not replaced:    (a) Foundry #1, on or about and at times preceding to March 30, 2016, welding cables had damaged insulation exposing bare wires throughout the cable, creating a shock hazard.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $600 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1000(c): An employee(s) was exposed to respirable silica in excess of the 8-hour time weighted average limits of based on silica calculation listed in Table Z-3:    (a)   In Foundry #1 copper casting cleaning area, on or about March 30, 2016, an employee who was operating a die grinder when cleaning copper castings was exposed to respirable silica at an 8 hour Time-Weighted Average level of 0.89 mg/m3, which is approximately 1.96 times the Permissible Exposure Limit for respirable silica of 0.455 mg/m3.  The exposure level is derived from a sample collected over a 428 minute sampling period; the calculations include a zero value for the 52 minutes not sampled.    (b) In Foundry #1 sand reclamation area, on or about March 30, 2016, an employee who was engaged in sand reclamation was exposed to respirable silica at an 8 hour Time-Weighted Average level of 0.865 mg/m3, which is approximately 1.12 times the Permissible Exposure Limit for respirable silica of 0.769 mg/m3. The exposure level is derived from a sample collected over a 415 minute sampling period; the calculations include a zero value for the 65 minutes not sampled.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 9010

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 Foundry #1 copper casting cleaning area, on or about March 30, 2016, feasible administrative or engineering controls were not provided for an employee who was operating a die grinder when cleaning copper castings was exposed to respirable silica at an 8 hour Time-Weighted Average level of 0.89 mg/m3, which is approximately 1.96 times the Permissible Exposure Limit for respirable silica of 0.455 mg/m3.  The exposure level is derived from a sample collected over a 428 minute sampling period; the calculations include a zero value for the 52 minutes not sampled.  (b) In Foundry #1 sand reclamation area, on or about March 30, 2016, feasible administrative or engineering controls were not provided for an employee who was engaged in sand reclamation was exposed to respirable silica at an 8 hour Time-Weighted Average level of 0.865 mg/m3, which is approximately 1.12 times the Permissible Exposure Limit for respirable silica of 0.769 mg/m3.  The exposure level is derived from a sample collected over a 415 minute sampling period; the calculations include a zero value for the 65 minutes not sampled.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 9010

General-duty citation text

29 CFR 1910.134(c)(1): A written respiratory protection program that included the provisions in 29 CFR 1910.134(c)(1)(i) - (ix) with worksite specific procedures was not established and implemented for required respirator use:   (a) In Foundry #1 copper casting cleaning area, on or about March 30, 2016, the employer did not implement a written respiratory protection program for an employee who was operating a die grinder when cleaning copper castings was exposed to respirable silica at an 8 hour Time-Weighted Average level of 0.89 mg/m3, which is approximately 1.96 times the Permissible Exposure Limit for respirable silica of 0.455 mg/m3.  The exposure level is derived from a sample collected over a 428 minute sampling period; the calculations include a zero value for the 52 minutes not sampled. For employee required to wear 3M 2071-P 95-half mask elastomeric respirator.  (b) In Foundry #1 sand reclamation area, on or about March 30, 2016, the employer did not implement a written respiratory protection program foran employee who was engaged in sand reclamation was exposed to respirable silica at an 8 hour Time-Weighted Average level of 0.865 mg/m3, which is approximately 1.57 times the Permissible Exposure Limit for respirable silica of 0.769 mg/m3. The exposure level is derived from a sample collected over a 415 minute sampling period; the calculations include a zero value for the 65 minutes not sampled. For employees required to wear a 3M 2071-P 95-half mask elastomeric respirator.  (c) In Foundry #1, mold filling and curing operations, on or about March 30, 2016, the employer did not implement a written respiratory protection program for employees who were required to utilize 3M 2071-P 95-half mask elastomeric respirators and for employees who were required to use respirators in areas where overexposures were not determined.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 9010

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 contaminant's chemical state and physical form:  (a)   In Foundry #1, on or about March 30, 2016, the respiratory hazards for potential exposure to silica, isocyanates from core pouring operations, shakeout operations, mold curing operations and forklift operations were not evaluated to determine potential employee exposures and respiratory protection requirements.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 9010

General-duty citation text

29 CFR 1910.134(g)(1)(i)(A): Respirators with tight-fitting facepieces were worn by employees who had facial hair that came between the sealing surface of the facepiece and the face or that interfered with valve function:  (a)   In Foundry #1, on or about March 30, 2016, an employee who was over-exposed to respirable silica had facial hair causing his 3M half mask respirator with 2071 P95 filter to not have a tight seal.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 9010

General-duty citation text

29 CFR 1910.134(k)(1): The employer did not provide effective training to ensure that each employee could demonstrate knowledge of 1910.134(k)(1)(i) - (vii):  (a) In Foundry #1, on or about March 30, 2016, respiratory training was not provided for employees required to wear 3M respirators with 2071 P95 filters.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(d)(2): An initial determination was not made to determine if any employee may be exposed to lead at or above the action level:    (a) Baxley foundry worksite, on or about January 14, 2016, foundry workers engaged in the copper pouring operation, including furnace deck operator, were not assessed to determine if exposed to lead at or above the action level.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 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) were not implemented to reduce and maintain employee exposure to lead :     (a) In the Plant facility pouring deck operations, on or about March 29, 2016, the employer did not implement engineering and work practice controls (including administrative controls) for an employee who was operating the furnace deck, was exposed to 0.238 mg/m3 of inorganic lead, which is approximately 4.7 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3. The exposure level is derived from a sample collected over a 440 minute sampling period; the calculations include a zero value for the 40 minutes not sampled.    (b) In the Plant facility pouring deck operations, on or about March 29, 2016, the employer did not implement engineering and work practice controls (including administrative controls) for an employee who was engaged in pouring operations, was exposed to 0. 0728 mg/m3 of inorganic lead, which is approximately 1.5 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3. The exposure level is derived from a sample collected over a 106 minute sampling period; the calculations include a zero value for the 374 minutes not sampled.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(f)(2)(i): The employer did not implement a respiratory protection program in accordance with 29 CFR 1910.134(b) through (d) (except (d)(1)(iii)), and (f) through (m) for each employee required by 29 CFR 1910.1025 to use a respirator:    (a) Foundry Operations, on or about and at times preceding to March 29, 2016, the employer did not implement a respiratory protection program for employees required to utilize 3M half mask respirators with 2071 3M P95 cartridges.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(f)(3)(i)(C): The employer did not provide HEPA filters for powered and non-powered air-purifying respirators:  (a) Baxley foundry worksite, on or about and at times preceding March 29, 2016, foundry workers engaged in the copper pouring operation, including furnace deck operator, were utilizing 3M 2071 P95 filters, which are not HEPA filters.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(g)(1): Appropriate protective work clothing and equipment were not provided at no cost to the employee when employee(s) were exposed to lead above the permissible exposure limit (PEL), without regard to the use of respirators, or where the possibility of skin or eye irritation exists:     (a) In the foundry facility, on or about March 29, 2016, an employee who was operating the furnace deck was exposed to 0.238 mg/m3 of inorganic lead, which is approximately 4.7 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3. The exposure level is derived from a sample collected over a 440 minute sampling period; the calculations include a zero value for the 40 minutes not sampled. Employee was not provided footwear, gloves, and work clothing free of charge.    (b) In the Plant facility pouring deck operations, on or about March 29, 2016, an employee who was engaged in pouring operations was exposed to 0. 0728 mg/m3 of inorganic lead, which is approximately 1.5 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3. The exposure level is derived from a sample collected over a 106 minute sampling period; the calculations include a zero value for the 374 minutes not sampled. Employee was not provided footwear, gloves, and work clothing free of charge.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(g)(2)(i): Protective clothing required in 29 CFR 1910.1025(g)(1) was not provided in a clean and dry condition at least daily to employee(s) whose exposure levels, without regard to a respirator, exceeded two hundred micrograms per cubic meter as an eight hour time weighted average:  (a) In the foundry facility, on or about March 29, 2016, clean clothing was not provided on a daily basis for an employee who was operating the furnace deck, was exposed to 0.238 mg/m3 of inorganic lead, which is approximately 4.7 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3. The exposure level is derived from a sample collected over a 440 minute sampling period; the calculations include a zero value for the 40 minutes not sampled. Employee was wearing personal street clothes and footwear when working on furnace deck.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(h)(2)(i): Floors and/or other surfaces where lead accumulates were cleaned by the use of compressed air:    (a) In Foundry #1 and Foundry #2, on or about March 29, 2016, compressed air was used for cleaning work stations and areas where lead accumulates throughout the work day.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(h)(2)(ii): Shoveling, sweeping or brushing methods were used to remove lead accumulations where vacuuming or other equally effective method was not evaluated:  (a) In Foundry #1 and Foundry #2, on or about March 29, 2016, dry sweeping and shoveling to remove lead accumulations were conducted during cleaning operations that occurred throughout the work day.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(i)(2)(i): Clean change rooms were not provided for employees exposed to lead in excess of the permissible exposure limit (PEL), without regard to the use of respirators:    (a) In the foundry facility, on or about March 29, 2016, clean change rooms were not provided for an employee who was operating the furnace deck and was exposed to 0.238 mg/m3 of inorganic lead, which is approximately 4.7 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3.  The exposure level is derived from a sample collected over a 440 minute sampling period; the calculations include a zero value for the 40 minutes not sampled. Employee was not provided access to a change room.    (b) In the Plant facility pouring deck operations, on or about March 29, 2016, clean change rooms were not provided for an employee who was engaged in pouring operations and was exposed to 0. 0728 mg/m3 of inorganic lead, which is approximately 1.5 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3.  The exposure level is derived from a sample collected over a 106 minute sampling period; the calculations include a zero value for the 374 minutes not sampled.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

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) In the foundry facility, on or about March 29, 2016, furnace operator was not required to shower at the end of the work shift when exposed to 0.238 mg/m3 of inorganic lead, which is approximately 4.7 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3.  The exposure level is derived from a sample collected over a 440 minute sampling period; the calculations include a zero value for the 40 minutes not sampled.   (b) In the Plant facility pouring deck operations, on or about March 29, 2016, an employee who was engaged in pouring operations was not required to shower at the end of the work shift when exposed to 0. 0728 mg/m3 of inorganic lead, which is approximately 1.5 times the Permissible Exposure Limit for inorganic lead of 0.05 mg/m3.  The exposure level is derived from a sample collected over a 106 minute sampling period; the calculations include a zero value for the 374 minutes not sampled.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(j)(1)(i): A medical surveillance program was not instituted for all employee(s) who were, or could be exposed to lead above the action level for more than thirty days per year:     (a) Foundry Operations, on or about and at times preceding to March 29, 2016, a medical surveillance program had not been initiated for employees who were, or could be exposed to lead above the action level for more than thirty days per year during copper pouring operations, furnace deck operations, and casting cleaning operations.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

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) Foundry Operations, on or about and at times preceding to March 29, 2016, blood sampling and analysis for lead and zinc protoporphyrin (ZPP) levels had not been performed for employees who were engaged in copper pouring operations, furnace deck operations, and casting cleaning operations.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(l)(1)(ii): The employer did not train each employee who is subject to exposure to lead at or above the action level, or for whom the possibility of skin or eye irritation exists, in accordance with the requirements of 29 CFR 1910.1025:     (a) Foundry Operations, on or about and at times preceding to March 29, 2016, employees whose exposure to lead was at or above the action level had not received training on lead hazards when engaged in copper pouring operations, furnace deck operations, and casting cleaning operations.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(m)(2)(i): 29 CFR 1910.1025(m)(2)(i): Warning signs bearing the legend: WARNING, LEAD WORK AREA, POISON, NO SMOKING OR EATING, were not posted in each work area where the permissible exposure limit (PEL) was exceeded:                                                     (a) In the Foundry Facility #2, on or about March 29, 2016, warning signs were not posted in areas where employees lead exposure levels exceeded the PEL during furnace deck and copper pouring operations.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1200(e)(1): Employer had not developed or implemented a written hazard communication program included the requirements outlined in 29 CFR 1910.1200(e)(1)(i) and (e)(1)(ii):     (a) Foundry Facility #1 & #2, on or about and at times preceding to January 14, 2016, a written hazard communication program had not been developed for workplace chemicals such as but not limited to: crystalline silica, copper coated gouging electrodes, Uniset F/X B- Part 2, Uniset Accelerator 5535, silicone carbide, Refcohol 3010, Refcohol 2530, Carbon and Alloy Steels, SP 1000 Red Armorchem SP, Calcined Petroleum Coke, and copper alloys.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $2,800 · Current $500 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:    (a) Foundry Facility #1 & #2, on or about and at times preceding to January 14, 2016, the employer did not provide effective information and training for workplace chemicals such as but not limited to: crystalline silica, copper coated gouging electrodes, Uniset F/X B- Part 2, Uniset Accelerator 5535, silicone carbide, Refcohol 3010, Refcohol 2530, Carbon and Alloy Steels, SP 1000 Red Armorchem SP, Calcined Petroleum Coke, and copper alloys.

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(2): Each exit was not clearly visible and marked by a sign reading "Exit":  (a) Foundry #2, on or about and at times preceding to March 29, 2016, exits within the facility were not identified with a sign reading "Exit".

Issued

Jul 7, 2016

Abate by

Aug 2, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(3): Complete inspections of the crane was not being performed at intervals as generally defined in paragraph (j)(1)(ii)(b) of this section:  (a) Foundry #1 and Foundry #2, on or about and at times preceding to March 29, 2016, gantry 5 ton crane inspections were not maintained and documented as being conducted.