OSHA Inspection: WAUPACA FOUNDRY, INC.

Issued

Nov 2, 2021

Abate by

Feb 28, 2025

Penalty

Initial $9,753 · Current $14,502

Hazardous substances 8110

General-duty citation text

29 CFR  1910.95(b)(1): When employees are subjected to sound exceeding those listed in Table G-16, feasible administrative or engineering controls shall be utilized. If such controls fail to reduce sound levels within the levels of Table G-16, personal protective equipment shall be provided and used to reduce sound levels within the levels of the table:  At the facility located at 805 Ogden Street, Marinette, WI 54143; feasible administrative or engineering controls were not utilized to reduce sound levels within the levels of Table G-16 of 29 CFR 1910.95 for instances such as, but not limited to:  a)  In Shakeout Line 2 area, a Shakeout employee was exposed to noise at 1091.4% (noise dose) of the allowable noise dose of 100% during a sample period of 476 minutes during one shift on June 30, 2021. A noise dose of 1091.4% is equivalent to an 8-hour TWA sound level of 107.2 dBA.  b)  In Shakeout Line 3 area, a Shakeout employee was exposed to noise at 1262.6% (noise dose) of the allowable noise dose of 100% during a sample period of 480 minutes during one shift on June 30, 2021. A noise dose of 1262.6% is equivalent to an 8-hour TWA sound level of 108.3 dBA.  c)  In Shakeout Line 4 area, a Shakeout employee was exposed to noise at 1144.5% (noise dose) of the allowable noise dose of 100% during a sample period of 480 minutes during one shift on June 30, 2021. A noise dose of 1144.5% is equivalent to an 8-hour TWA sound level of 107.6 dBA.  d)  In Shakeout Line 5 area, a Shakeout employee was exposed to noise at 1826.4% (noise dose) of the allowable noise dose of 100% during a sample period of 480 minutes during one shift on June 30, 2021. A noise dose of 1826.4% is equivalent to an 8-hour TWA sound level of 111.0 dBA.  e)  In Shakeout Line 6 area, a Shakeout employee was exposed to noise at 966.4% (noise dose) of the allowable noise dose of 100% during a sample period of 466 minutes during one shift on June 30, 2021. A noise dose of 966.4% is equivalent to an 8-hour TWA sound level of 106.3 dBA.  f)  In Shakeout Lines 1-6 areas, a Shakeout Floater employee was exposed to noise at 1822.7% (noise dose) of the allowable noise dose of 100% during a sample period of 480 minutes during one shift on June 30, 2021. A noise dose of 1822.7% is equivalent to an 8-hour TWA sound level of 110.9 dBA.  g)  In the Pattern Cleaning area, an Ice Blaster employee was exposed to noise at 1152.3% (noise dose) of the allowable noise dose of 100% during a sample period of 480 minutes during one shift on June 30, 2021. A noise dose of 1152.3% is equivalent to an 8-hour TWA sound level of 107.6 dBA.

Issued

Nov 2, 2021

Abate by

Sep 2, 2025

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(c):  The employer shall ensure that no employee is exposed to an airborne concentration of respirable crystalline silica in excess of 50 mg/m^3, calculated as an 8-hour TWA:  At the facility located at 805 Ogden Street, Marinette, WI 54143;  a)  In Shakeout Line 3 area, a Shakeout employee was exposed to respirable crystalline silica at an average concentration of 59 �g/m^3 on June 29, 2021, approximately 1.2 times the PEL of 50 �g/m^3. This exposure was derived from one sample collected over 489 minutes.  b)  In Shakeout Line 5 area, a Shakeout employee was exposed to respirable crystalline silica at an average concentration of 70 �g/m^3 on June 29, 2021, approximately 1.4 times the PEL of 50 �g/m^3. This exposure was derived from one sample collected over 493 minutes.  c)  In Shakeout Line 6 area, a Shakeout employee was exposed to respirable crystalline silica at an average concentration of 89 �g/m^3 on June 29, 2021, approximately 1.8 times the PEL of 50 �g/m^3. This exposure was derived from one sample collected over 489 minutes.  d)  In Shakeout Line 1-6 areas, a Shakeout Floater employee was exposed to respirable crystalline silica at an average concentration of 61 �g/m^3 on June 29, 2021, approximately 1.2 times the PEL of 50 �g/m^3. This exposure was derived from one sample collected over 491 minutes.

Issued

Nov 2, 2021

Abate by

Sep 2, 2025

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(f)(1):  The employer shall use engineering and work practice controls to reduce and maintain employee exposure to respirable crystalline silica to or below the PEL, unless the employer can demonstrate that such controls are not feasible. Wherever such feasible engineering and work practice controls are not sufficient to reduce employee exposure to or below the PEL, the employer shall nonetheless use them to reduce employee exposure to the lowest feasible level and shall supplement them with the use of respiratory protection that complies with the requirements of paragraph (g) of this section:  At the facility located at 805 Ogden Street, Marinette, WI 54143; the employer did not use engineering and work practice controls to reduce and maintain employee exposures to respirable crystalline silica to or below the PEL when Shakeout employees (lines 3, 5 and 6) and Shakeout Floater employees (rotating between lines 1-6) worked in the Shakeout line areas separating castings from gating and dry sweeping below the lines.

Issued

Nov 2, 2021

Abate by

Feb 28, 2025

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(h)(1):  The employer shall not allow dry sweeping or dry brushing where such activity could contribute to employee exposure to respirable crystalline silica unless wet sweeping, HEPA-filtered vacuuming or other methods that minimize the likelihood of exposure are not feasible:  At the facility located at 805 Ogden Street, Marinette, WI 54143; the employer allowed dry sweeping which could have contributed to employee exposure to respirable crystalline silica when other methods that minimize the likelihood of exposure were feasible when Shakeout employees would dry sweep in the pits below the Shakeout lines where fugitive sand from the Shakeout process was present.

Issued

Nov 2, 2021

Abate by

Feb 28, 2025

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(h)(2)(i): The employer shall not allow compressed air to be used to clean clothing or surfaces where such activity could contribute to employee exposure to respirable crystalline silica unless compressed air is used in conjunction with a ventilation system that effectively captures the dust cloud created by the compressed air:  At the facility located at 805 Ogden Street, Marinette, WI 54143; the employer allowed compressed air to be used at the sweeper truck cleaning area to clean sweeper trucks, which could contribute to employee exposure to respirable crystalline silica. An exhaust ventilation side-draft hood was used at the cleaning area; however, the side-draft hood did not effectively capture the dust cloud created by the compressed air.