OSHA Inspection: AFW FOUNDRY INC

Issued

Sep 2, 2022

Abate by

Sep 15, 2022

Penalty

Initial $10,151 · Current $5,000 Reduced

General-duty citation text

29 CFR  1910.22(a)(3):29 CFR 1910.22(a)(3): The employer did not ensure that walking-working surfaces are maintained free of hazards such as sharp or protruding objects, loose boards, corrosion, leaks, spills, snow, and ice.  (a) On or about April 27, 2022, in the pallet line section of the production floor near the sand recycling system, a gap on the floor directly over a moving conveyor measuring approximately 10" x 33" and visually estimated to be approximately 6" deep was present where employees performed work.  A pallet line laborer was exposed to tripping, falling, and entanglement hazards posed by the gap over the conveyor. The employee was also potentially exposed to struck-by and burn hazards from carrying a crucible containing molten metal around the gap over the conveyor, in the event of a trip, fall, and/or entanglement due to the exposed gap.  (b) On or about April 27, 2022, in the pallet line section of the production floor near the sand recycling system, a gap on the floor directly over a moving conveyor measuring approximately 10" x 33" and visually estimated to be approximately 6" deep was present where employees performed work.  A pallet line laborer was exposed to tripping, falling, and entanglement hazards posed by the gap over the conveyor. The employee was also potentially exposed to struck-by and burn hazards from carrying a crucible containing molten metal around the gap over the conveyor, in the event of a trip, fall, and/or entanglement due to the exposed gap.  (c) On or about April 27,2022 in the pallet line section of the production floor near the sand recycling system, a gap on the floor directly over a moving conveyor measuring approximately 10" x 33" and visually estimated to be approximately 6" deep was present where employees performed work.  A pallet line laborer was exposed to tripping, falling, and entanglement hazards posed by the gap over the conveyor. The employee was also potentially exposed to struck-by and burn hazards from carrying a crucible containing molten metal around the gap over the conveyor, in the event of a trip, fall, and/or entanglement due to the exposed gap.

Issued

Sep 2, 2022

Abate by

Sep 9, 2022

Penalty

Initial $10,151 · Current $5,000 Reduced

General-duty citation text

29 CFR  1910.132(d)(1)(i):The employer did not select and have each affected employee use, the types of personal protective equipment that would protect the affected employee(s) from the hazards identified in the hazard assessment:  (a) On April 27, 2022, in the pallet line, a pallet line laborer was observed pouring a crucible containing molten metal without the use of FR attire and face shield, as required in the hazard assessment, exposing the employee to severe burn hazards.  (b) On April 27, 2022, in the pallet line, a pallet line laborer was observed pouring a crucible containing molten metal without the use of FR attire and face shield, as required in the hazard assessment, potentially exposing the employee to burn hazards.

Issued

Sep 2, 2022

Abate by

Sep 9, 2022

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.138(a): The employer did not select and require employee(s) to use appropriate hand protection when employees' hands were exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasion; punctures; chemical burns; thermal burns; and harmful temperature extremes.  (a) On April 27, 2022, in the pallet line, a pallet line laborer was observed pouring a crucible containing molten metal without the use of leather gloves for hand protection, exposing the employees hands to burn hazards.  (b) On April 27th 2022, in the pallet line, a pallet line laborer was observed pouring a crucible containing molten metal without the use of leather gloves for hand protection, exposing the employees hands to burn hazards.

Issued

Sep 2, 2022

Abate by

Mar 7, 2023

Penalty

Initial $10,151 · Current $10,000 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(c): The employer did not ensure that no employee was exposed to an airborne concentration of respirable crystalline silica in excess of 50 micrograms/m3, calculated as an 8-hour TWA:  a) On or about April 27, 2022, the employee operating Squisher #2 was exposed to respirable crystalline silica (RCS) at an 8-hour time weighted average (TWA) of 59 micrograms per cubic meter of air, approximately 1.18 times the limit of 50 micrograms per cubic meter of air. The sample was collected during a 407 minute sampling period, and exposure calculations include a zero increment for the 73 minutes not sampled.  b) On or about April 27, 2022, the employee operating the pallet line was exposed to respirable crystalline silica (RCS) at an 8-hour time weighted average (TWA) of 80 micrograms per cubic meter of air, approximately 1.6 times the limit of 50 micrograms per cubic meter of air. The sample was collected during a 395 minute sampling period, and exposure calculations include a zero increment for the 85 minutes not sampled.

Issued

Sep 2, 2022

Abate by

Mar 7, 2023

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(f)(1): The employer did not 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:  On or about April 27, 2022, and days prior, employees performed work on the shop floor while being exposed to airborne concentration of respirable crystalline quartz silica above the 8-hour time weighted average of 50 micrograms per cubic meter of air (ug/m^3)., without effective work practice controls and/or engineering controls.  a) On or about April 27, 2022, the employee operating Squisher #2 was exposed to respirable crystalline silica (RCS) at an 8-hour time weighted average (TWA) of 59 micrograms per cubic meter of air, approximately 1.18 times the limit of 50 micrograms per cubic meter of air. The sample was collected during a 407 minute sampling period, and exposure calculations include a zero increment for the 73 minutes not sampled.  b) On or about April 27, 2022, the employee operating the pallet line was exposed to respirable crystalline silica (RCS) at an 8-hour time weighted average (TWA) of 80 micrograms per cubic meter of air, approximately 1.6 times the limit of 50 micrograms per cubic meter of air. The sample was collected during a 395 minute sampling period, and exposure calculations include a zero increment for the 85 minutes not sampled.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $6,164 · Current $0 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(g)(2): Where respirator use was required by this section, the employer did not institute a respiratory protection program in accordance with 29 CFR 1910.134:  a) On or about April 27, 2022, the employee operating Squisher #2 was exposed to respirable crystalline silica (RCS) at an 8-hour time weighted average (TWA) of 59 micrograms per cubic meter of air, approximately 1.18 times the limit of 50 micrograms per cubic meter of air. The sample was collected during a 407 minute sampling period, and exposure calculations include a zero increment for the 73 minutes not sampled. The employer did not ensure all elements of a respiratory protection program were implemented, such as medical evaluation, fit testing and training, to ensure that the employee properly utilized a 3M N95 mask and Half face elastomeric respirator to prevent exposure above the OSHA PEL for respirable crystalline silica.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.134(d)(3)(ii): The employer did not provide a respirator that was appropriate for the chemical state and physical form of the contaminant:  (a) On or about April 27, 2022, employees working in areas that required respiratory protection were observed wearing respiratory protection that was inadequate to meet the facility's respiratory protection program and respirable crystalline silica standard, such as surgical masks, cloth masks, or failure to wear any form of respiratory protection.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

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) On or about April 27, 2022, an employee operating the pallet line was wearing a tight-fitting filtering facepiece (N95) with visible facial hair that came between the sealing surface of the facepiece and the face.  (b) On or about April 27, 2022, an employee working in the grinding area was required to wear a tight-fitting filtering facepiece (N95) with visible facial hair that came between the sealing surface of the facepiece and the face.  (c) On or about April 27, 2022, an employee operating the squisher was required to wear a tight-fitting filtering facepiece (N95) with visible facial hair that came between the sealing surface of the facepiece and the face.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $6,164 · Current $0 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(h)(1): The employer allowed dry sweeping or dry brushing where such activity could contribute to employee exposure to respirable crystalline silica and wet sweeping, HEPA-filtered vacuuming or other methods that minimize the likelihood of exposure were feasible:  (a) On or about May 10, 2022, employees in the squisher and mold areas utilized a broom to sweep the area clear of sand, potentially creating airborne exposures to respirable crystalline silica.

Issued

Sep 2, 2022

Abate by

Oct 11, 2022

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.1053(h)(2)(i): The employer did not prohibit compressed air to be used to clean clothing or surfaces where such activity could contribute to employee exposure to respirable crystalline silica without being used in conjunction with a ventillation system to capture blown dust:   a) On or about May 10th 2022, at the mold and squeeze area of the production floor at the mold and squeeze machine, an employee was observed using compressed air to clean the molds of sand, exposing employees to respirable crystalline silica.  b) On or about May 10th 2022, at the mold and squeeze area of the production floor at the mold and squeeze machine, an employee was observed using compressed air to clean the molds of sand, potentially exposing employees to respirable crystalline silica.

Issued

Sep 2, 2022

Abate by

Oct 11, 2022

Penalty

Initial $10,151 · Current $0 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(i)(1)(i): Medical surveillance - The employer did not make medical surveillance available at no cost to the employee, and at a reasonable time and place, for each employee who will be occupationally exposed to respirable crystalline silica at or above the action level for 30 or more days per year.  (a) On or about March 29, 2022, and days prior, the employer had not provided medical surveillance for each employee who was occupationally exposed to respirable crystalline silica at or above the action level for 30 days or more per year, including, but not limited to employees in the Pallet Line, Squeezer Molder, Furnace, DISA Shakeout/Knockout, and Grinder/Squeezer Molder Assembler areas.

Issued

Sep 2, 2022

Abate by

Oct 11, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(i)(2): The employer did not make available an initial (baseline) medical examination within 30 days after initial assignment when the employee had not received a medical examination that meets the requirements of this section within the last three years:  (a) On or about March 29, 2022, and days prior, the employer had not provided an initial (baseline) medical examination within 30 days after initial assignment for each employee who would be occupationally exposed to respirable crystalline silica at or above the action level for 30 days or more per year, including, but not limited to employees in the Pallet Line, Squeezer Molder, Furnace, DISA Shakeout/Knockout, and Grinder/Squeezer Molder Assembler areas.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $6,164 · Current $5,000 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(j)(1):The employer did not include respirable crystalline silica in the program established to comply with the hazard communication standard (HCS) (29 CFR 1910.1200):    a) On or about March 30, 2022, and days prior, the employer-provided hazard communication program failed to include information on respirable crystalline silica hazards.  Employees performed work in an environment in which they were exposed to airborne respirable crystalline silica without proper training from the hazard communication program, to include the hazards presented by, effective engineering controls to reduce airborne exposure to, and proper PPE for protection from respirable crystalline silica.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(j)(3)(i): The employer did not ensure that each employee covered by this section could demonstrate knowledge and understanding of the contents of this section.   (a) On or about March 29, 2022, and days prior, the employer did not ensure that each employee affected by respirable crystalline silica could demonstrate knowledge and understanding of the health hazards associated with exposure to respirable crystalline silica.   (b) On or about March 29, 2022, and days prior, the employer did not ensure that each employee affected by respirable crystalline silica could demonstrate knowledge and understanding of specific tasks in the workplace that could result in exposure to respirable crystalline silica.  (c) On or about March 29, 2022, and days prior, the employer did not ensure that each employee affected by respirable crystalline silica could demonstrate knowledge and understanding of specific measures the employer has implemented to protect employees from exposure to respirable crystalline silica, including engineering controls, work practices, and respirators to be used.   (d) On or about March 29, 2022, and days prior, the employer did not ensure that each employee affected by respirable crystalline silica could demonstrate knowledge and understanding of the purpose and a description of the medical surveillance program.

Issued

Sep 2, 2022

Abate by

Sep 23, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1200(e)(1)(i): The employer did not compile a list of the hazardous chemicals known to be present using a product identifier that was referenced on the appropriate safety data sheet.  (a) On or about March 29, 2022, and days prior, the employer did not compile a chemical inventory that included respirable crystalline silica.

Issued

Sep 2, 2022

Abate by

Oct 11, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

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) On or about March 29, 2022, and days prior, employees were not provided effective information and training on respirable crystalline silica in their work areas at the time of their initial assignment or days following.

Issued

Sep 2, 2022

Abate by

Sep 29, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(d)(6)(i): Within 15 working days after completing an exposure assessment in accordance with paragraph (d) of this section, the employer did not individually notify each affected employee in writing of the results of that assessment or post the results in an appropriate location accessible to all affected employees:  (a) On or about May 10, 2022, the results of an exposure assessment conducted on November 29, 2021 for occupational exposure to respirable crystalline silica and received by the employer on February 2, 2022 was not provided to each affected employee in the facility.