OSHA Inspection: HORSEHEAD CORPORATION

Issued

2014-12-22 00:00:00

Abate by

2026-06-30 00:00:00

Penalty

Initial $2805.00 · Current $1950.00 Reduced

Hazardous substances 9135Z102

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of total dust and zinc oxide listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 15 milligrams per cubic meter of air:    a) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to total dust at an 8-hour time-weighted average of 78.0 milligrams per cubic meter of air, approximately 5.2  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.      b) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to zinc oxide at an 8-hour time-weighted average of 20.0 milligrams per cubic meter of air, approximately 1.3  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.      c) Horsehead Corporation, Palmerton, PA:  An employee, Calcine Utility, was exposed to total dust at an 8-hour time-weighted average of 29.0 milligrams per cubic meter of air, approximately 1.9 times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 335 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.      d) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to total dust at an 8-hour time-weighted average of 80.0 milligrams per cubic meter of air, approximately 5.3  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.      e) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to zinc oxide at an 8-hour time-weighted average of 21.0 milligrams per cubic meter of air, approximately 1.4  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.        ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

2014-12-22 00:00:00

Abate by

2026-06-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9135Z102

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) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to total dust at an 8-hour time-weighted average of 78.0 milligrams per cubic meter of air, approximately 5.2  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for total dust.    b) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to zinc oxide at an 8-hour time-weighted average of 20.0 milligrams per cubic meter of air, approximately 1.3  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for zinc oxide.    c) Horsehead Corporation, Palmerton, PA:  An employee, Calcine Utility, was exposed to total dust at an 8-hour time-weighted average of 29.0 milligrams per cubic meter of air, approximately 1.9 times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 335 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for total dust.    d) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to total dust at an 8-hour time-weighted average of 80.0 milligrams per cubic meter of air, approximately 5.3  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for total dust.    e) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to zinc oxide at an 8-hour time-weighted average of 21.0 milligrams per cubic meter of air, approximately 1.4  times the Permissible Exposure Limit of 15 milligrams per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for zinc oxide.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED      GENERAL METHODS OF CONTROL APPLICABLE IN THESE CIRCUMSTANCES INCLUDE, BUT ARE NOT LIMITED TO, THE FOLLOWING:    Pelletizer:    - Reduce the drop height of EAF dust conveyed onto the pelletizer pan and ensure that local ventilation hood is located close enough to capture dust generated by the drop.  - Reduce the drop height of EAF pellets conveyed onto the ground.  - Increase ventilation at the pelletizer pans.  - Optimize baghouse B8 efficiency by re-installing diaphragm valves used as a cleaning mechanism.  - Install a second control valve for the pelletizer water feed inside the pelletizer shanty.  - Prevent spillage by enclosing all mechanical conveyor belts transferring dust and zinc oxide and containing material.  - Increase scheduled maintenance for pelletizer ventilation system.  - Place the pelletizer shanty under HEPA filtered positive pressure.  - Ensure that video equipment in the pelletizer shanty monitors all locations the employee is required to maintain.    Calcine Utility:    - Repair leaks in kiln screw conveyors.  - Perform routine clean-up of spilled lead containing material on the work floor adjacent to the calcine utility shanty and below the kiln screw conveyor systems.  - Utilize a forklift with an enclosed cab under HEPA filtered positive pressure to empty kiln dust boxes.  - Ensure that video equipment in the calcine utility shanty monitors all locations the employee is required to maintain.  - Prevent spillage by enclosing all mechanical conveyor belts transferring dust containing material.      Abatement Schedule:    Step 1.  A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced in this citation.  This plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation:    (1)  Evaluation of engineering/administrative control options;  (2)  Selection of optimum control methods and completion of design;  (3)  Procurement, installation, and operation of selected control measures;  (4)  Testing and acceptance or modification/redesign of controls.      All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.  45-day progress reports are required during the abatement period.    Step 2.  Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.

Issued

2014-12-22 00:00:00

Abate by

2026-06-30 00:00:00

Penalty

Initial $4675.00 · Current $3275.00 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(c)(1): Employee(s) were exposed to lead at concentrations greater than fifty micrograms per cubic meter of air averaged over an eight-hour period:    a) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to lead at an 8-hour time-weighted average of 570.0 micrograms per cubic meter of air, approximately 11.4 times the Permissible Exposure Limit of 50 micrograms per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.      b) Horsehead Corporation, Palmerton, PA:  An employee, Calcine Utility, was exposed to lead at an 8-hour time-weighted average of 550.0 micrograms per cubic meter of air, approximately 11.0 times the Permissible Exposure Limit of 50 micrograms per cubic meter of air.  Sampling was performed for 335 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.      c) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to lead at an 8-hour time-weighted average of 290.0 micrograms per cubic meter of air, approximately 5.8 times the Permissible Exposure Limit of 50 micrograms per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.        ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

2014-12-22 00:00:00

Abate by

2026-06-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

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 where engineering and work practice controls (including administrative controls) were feasible but did not reduce the employees' exposure to or below the permissible exposure limit the employer did not use engineering and/or work practice controls to reduce esposures to the lowest feasible level:    a) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to lead at an 8-hour time-weighted average of 570.0 micrograms per cubic meter of air, approximately 11.4 times the Permissible Exposure Limit of 50 micrograms per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for lead.    b) Horsehead Corporation, Palmerton, PA:  An employee, Calcine Utility, was exposed to lead at an 8-hour time-weighted average of 550.0 micrograms per cubic meter of air, approximately 11.0 times the Permissible Exposure Limit of 50 micrograms per cubic meter of air.  Sampling was performed for 335 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for lead.    c) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to lead at an 8-hour time-weighted average of 290.0 micrograms per cubic meter of air, approximately 5.8 times the Permissible Exposure Limit of 50 micrograms per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for lead.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED      GENERAL METHODS OF CONTROL APPLICABLE IN THESE CIRCUMSTANCES INCLUDE, BUT ARE NOT LIMITED TO, THE FOLLOWING:    Pelletizer:    - Reduce the drop height of EAF dust conveyed onto the pelletizer pan and ensure that local ventilation hood is located close enough to capture dust generated by the drop.  - Reduce the drop height of EAF pellets conveyed onto the ground.  - Increase ventilation at the pelletizer pans.  - Optimize baghouse B8 efficiency by re-installing diaphragm valves used as a cleaning mechanism.  - Install a second control valve for the pelletizer water feed inside the pelletizer shanty.  - Prevent spillage by enclosing all mechanical conveyor belts transferring lead containing material.  - Increase scheduled maintenance for pelletizer ventilation system.  - Place the pelletizer shanty under HEPA filtered positive pressure.  - Ensure that video equipment in the pelletizer shanty monitors all locations the employee is required to maintain.    Calcine Utility:    - Repair leaks in kiln screw conveyors.  - Perform routine clean-up of spilled lead containing material on the work floor adjacent to the calcine utility shanty and below the kiln screw conveyor systems.  - Utilize a forklift with an enclosed cab under HEPA filtered positive pressure to empty kiln dust boxes.  - Ensure that video equipment in the calcine utility shanty monitors all locations the employee is required to maintain.  - Prevent spillage by enclosing all mechanical conveyor belts transferring lead containing material.      Abatement Schedule:    Step 1.  A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced in this citation.  This plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation:    (1)  Evaluation of engineering/administrative control options;  (2)  Selection of optimum control methods and completion of design;  (3)  Procurement, installation, and operation of selected control measures;  (4)  Testing and acceptance or modification/redesign of controls.      All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.  45-day progress reports are required during the abatement period.    Step 2.  Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.

Issued

2014-12-22 00:00:00

Abate by

2026-06-30 00:00:00

Penalty

Initial $4675.00 · Current $3275.00 Reduced

Hazardous substances C141

General-duty citation text

29 CFR 1910.1027(c): The employer did not ensure that no employee was exposed to an airborne concentration of cadmium in excess of five micrograms per cubic meter of air (5ug/m3), calculated as an eight-hour time-weighted average (TWA):    a) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to cadmium at an 8-hour time-weighted average of 140.0 micrograms per cubic meter of air, approximately 28.0  times the Permissible Exposure Limit of 5 micrograms per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.    b) Horsehead Corporation, Palmerton, PA:  An employee, Calcine Utility, was exposed to cadmium at an 8-hour time-weighted average of 120.0 micrograms per cubic meter of air, approximately 24.0 times the Permissible Exposure Limit of 5 micrograms per cubic meter of air.  Sampling was performed for 335 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.    c) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to cadmium at an 8-hour time-weighted average of 370.0 micrograms per cubic meter of air, approximately 74.0 times the Permissible Exposure Limit of 5 micrograms per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

2014-12-22 00:00:00

Abate by

2026-06-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances C141

General-duty citation text

29 CFR 1910.1027(f)(1)(i): The employer did not implement engineering and work practice controls to reduce and maintain employee exposure to cadmium at or below the permissible exposure limit (PEL):    a) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to cadmium at an 8-hour time-weighted average of 140.0 micrograms per cubic meter of air, approximately 28.0  times the Permissible Exposure Limit of 5 micrograms per cubic meter of air.  Sampling was performed for 340 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for cadmium.    b) Horsehead Corporation, Palmerton, PA:  An employee, Calcine Utility, was exposed to cadmium at an 8-hour time-weighted average of 120.0 micrograms per cubic meter of air, approximately 24.0 times the Permissible Exposure Limit of 5 micrograms per cubic meter of air.  Sampling was performed for 335 minutes on October 17, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for cadmium.    c) Horsehead Corporation, Palmerton, PA:  An employee, Pelletizer, was exposed to cadmium at an 8-hour time-weighted average of 370.0 micrograms per cubic meter of air, approximately 74.0 times the Permissible Exposure Limit of 5 micrograms per cubic meter of air.  Sampling was performed for 343 minutes on October 24, 2014.  Zero exposure was assumed for the unsampled period of time.  The employer did not implement feasible engineering controls and/or work practice controls to reduce employee exposure levels to below the Permissible Exposure Limit for cadmium.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED      GENERAL METHODS OF CONTROL APPLICABLE IN THESE CIRCUMSTANCES INCLUDE, BUT ARE NOT LIMITED TO, THE FOLLOWING:    Pelletizer:    - Reduce the drop height of EAF dust conveyed onto the pelletizer pan and ensure that local ventilation hood is located close enough to capture dust generated by the drop.  - Reduce the drop height of EAF pellets conveyed onto the ground.  - Increase ventilation at the pelletizer pans.  - Optimize baghouse B8 efficiency by re-installing diaphragm valves used as a cleaning mechanism.  - Install a second control valve for the pelletizer water feed inside the pelletizer shanty.  - Prevent spillage by enclosing all mechanical conveyor belts transferring cadmium containing material.  - Increase scheduled maintenance for pelletizer ventilation system.  - Place the pelletizer shanty under HEPA filtered positive pressure.  - Ensure that video equipment in the pelletizer shanty monitors all locations the employee is required to maintain.    Calcine Utility:    - Repair leaks in kiln screw conveyors.  - Perform routine clean-up of spilled lead containing material on the work floor adjacent to the calcine utility shanty and below the kiln screw conveyor systems.  - Utilize a forklift with an enclosed cab under HEPA filtered positive pressure to empty kiln dust boxes.  - Ensure that video equipment in the calcine utility shanty monitors all locations the employee is required to maintain.  - Prevent spillage by enclosing all mechanical conveyor belts transferring cadmium containing material.      Abatement Schedule:    Step 1.  A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced in this citation.  This plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation:    (1)  Evaluation of engineering/administrative control options;  (2)  Selection of optimum control methods and completion of design;  (3)  Procurement, installation, and operation of selected control measures;  (4)  Testing and acceptance or modification/redesign of controls.      All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.  45-day progress reports are required during the abatement period.    Step 2.  Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.