OSHA Inspection: LIBERTY CASTING COMPANY, LLC

Issued

2019-09-25 00:00:00

Penalty

Initial $5626.00 · Current $3972.00 Reduced

General-duty citation text

29 CFR 1910.23(b): General requirements for all ladders. The employer must ensure:     29 CFR 1910.23(b)(1): Ladder rungs, steps, and cleats are parallel, level, and uniformly spaced when the ladder is in position for use;    On or about May 7, 2019, the fixed ladder used for access to the North Core Room mezzanine platform had ladder rungs that were not parallel, level and uniformly spaced due to damage. The ladder was bent and the lowest three rungs were not parallel, level or spaced uniformly due to the damage.

Issued

2019-09-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $5626.00 · Current $3871.00 Reduced

General-duty citation text

29 CFR 1910.25(b)(1): (1) Handrails, stair rail systems, and guardrail systems are provided in accordance with 29 CFR 1910.28;    a. On or about May 30, 2019, the fixed stairway located north of the Mold Wash work station/position on the Main Line conveyor platform was not provided a stair rail system for the open side of the fixed stairway.       b. On or about May 30, 2019, the fixed stairway located south of the Clean-out work station/position on the Main Line conveyor platform had a stairway rail system that was missing a midrail.      Due to these conditions, employees were subject to low level fall hazards during stairway use to access or egress from the Main Line conveyor platform.

Issued

2019-09-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.25(b) Stairways. General requirements. The employer must ensure:   29 CFR 1910.25(b)(3): (3) Stairs have uniform riser heights and tread depths between landings;     a. On or about May 30, 2019, the fixed stairway located south of the Clean-out work station/position on the Main Line conveyor platform had the first tread that was damaged, partially broken apart from the attachment point to the stairwall and was not of uniform riser height. Due to this condition, employees had exposure to a same level trip/fall hazard.

Issued

2019-09-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $9377.00 · Current $6564.00 Reduced

General-duty citation text

29 CFR 1910.28(b): Protection from fall hazards-   29 CFR 1910.28(b)(1): Unprotected sides and edges.   29 CFR 1910.28(b)(1)(i): Except as provided elsewhere in this section, the employer must ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is protected from falling by one or more of the following:    a. On or about May 7, 2019, the employer failed to provide fall protection for unprotected sides of the North Core Room Chemical Storage mezzanine at the center of the south facing side of mezzanine at the "bend" and beside the fixed ladder landing area. Due to these conditions, employees who accessed the platform were exposed to fall hazards of more than 6 feet to the concrete floor below.

Issued

2019-09-25 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.132(c): Design. All personal protective equipment shall be of safe design and construction for the work to be performed.    a. On or about April 8, 2019, general utility gloves coated with latex material were used by employees to perform Flow Coat job duties in coremaking production that included exposure to ignited flammable materials. These duties included spray application of flammable liquids and ignition of the applied flammable liquid with a butane torch. Due to the combustible material composition of the general utility gloves, employees have increased risk for burns to the hand during the performance of required job duties.      b. On or about April 8, 2019, general utility gloves coated with latex material were used by employees to perform Mold Wash job duties in moldmaking production that included exposure to ignited flammable materials. These duties included spray application of flammable liquids and ignition of the applied flammable liquid with a butane torch. Due to the combustible material composition of the general utility gloves, employees have increased risk for burns to the hand during the performance of required job duties.

Issued

2019-09-25 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 1560

General-duty citation text

29 CFR 1910.138(a): General requirements. Employers shall select and require employees to use appropriate hand protection when employees' hands are exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical burns; thermal burns; and harmful temperature extremes.    a. On or about April 8, 2019, the employer failed to select and require the use of hand protection against thermal burns for employees in coremaking process areas. Employees were exposed to thermal hazards and had an increased risk for burns due to the lack of appropriate PPE when applying the flammable Flow Coat materials and then igniting the applied material with a butane torch.    b. On or about April 8, 2019, the employer failed to select and require the use of hand protection against thermal burns for employees in moldmaking process areas. Employees were exposed to thermal hazards and had an increased risk for burns due to the lack of appropriate PPE when applying the flammable Mold Wash materials and then igniting the applied material with a butane torch.

Issued

2019-09-25 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

General-duty citation text

29 CFR 1910.147(d)(2): Machine or equipment shutdown. The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage.  a. On or about April 30, 2019, the Loop Line Mill Mixer was not turned off, or shut down prior to and in preparation for employees performing work duties covered by this part that included cleaning material from the auger section to "unjam" the material. During these covered activities, the Loop Line Mill Operator and the Loop Line Mill Helper were exposed to caught-in hazards associated with the mechanical energy associated with the internal auger assembly.

Issued

2019-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(f)(3)(ii)(D): Each authorized employee shall affix a personal lockout or tagout device to the group lockout device, group lockbox, or comparable mechanism when he or she begins work, and shall remove those devices when he or she stops working on the machine or equipment being serviced or maintained.   a. On or about April 30, 2019, employees involved with duties covered by this part failed to affix lockout devices or tagout devices prior to performing Loop Line Mill auger mechanism cleanout. During this covered activity, the Mill Operator and the Mill Helper were exposed to caught-in hazards posed by the internal auger mechanism component while the exterior housing (guarding) was removed. The equipment was not powered off, or shutdown during the performance of this activity.

Issued

2019-09-25 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

General-duty citation text

29 CFR 1910.219(f)(3): Sprockets and chains. All sprocket wheels and chains shall be enclosed unless they are more than seven (7) feet above the floor or platform. Where the drive extends over other machine or working areas, protection against falling shall be provided. This subparagraph does not apply to manually operated sprockets.  a. On or about May 30, 2019, there was a missing guard for protecting sprocket wheels and chains on the Main Line conveyor system adjacent to the fixed stairway for access to the Main Line Set-up work area. This unguarded sprocket wheel and chain was approximately three feet from the concrete floor and even with Main Line Set-up platform. Due to this condition, employees were exposed to caught-in and ingoing nip point hazards.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $5626.00 · Current $3938.00 Reduced

General-duty citation text

29 CFR 1910.242(b): Compressed air used for cleaning. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment.    a. On or about April 30, 2019, compressed air was used for cleaning purposes that was not reduced to an effective pressure of less than 30 psi.  A South Core Room employee performing coremaking job duties used a compressed air hand dispensing wand for cleaning that had dead end measured pressure of greater than 44 psi.      b. On or about April 30, 2019, compressed air was used for cleaning purposes that was not reduced to an effective pressure of less than 30 psi. A South Core Room employee used a compressed air hand dispensing wand for cleaning that had dead end measured pressure of greater than 60 psi.    Compressed air use that exceeded 30 psi posed an injection hazard to these employees.

Issued

2019-09-25 00:00:00

Penalty

Initial $9377.00 · Current $6564.00 Reduced

General-duty citation text

29 CFR 1910.303(b): Examination, installation, and use of equipment --  29 CFR 1910.303(b)(1): Examination. Electric equipment shall be free from recognized hazards that are likely to cause death or serious physical harm to employees. Safety of equipment shall be determined using the following considerations:  29 CFR 1910.303(b)(1)(iv): Electrical insulation;  a. On or about May 7, 2019, the electrical power supply flexible cable used to provide power for the Shaker Table had damaged insulation and was improperly repaired with standard electrical tape. The damaged flexible cable was subject to friction from concrete and metal surfaces and vibrational forces from the movement of the Shaker Table. Due to this condition, employees operating and/or working in close proximity to the Shaker Table controls were exposed to an electrical contact hazard.  b. On or about May 17, 2019, the electrical power supply flexible cable used to provide power for a limit switch on the Loop Line conveyor near the Clean-Out position had been damaged, was spliced and was improperly repaired with standard electrical tape. The damaged flexible cable was laying on the floor of the work area. Due to this condition, Loop Line employees were exposed to an electrical contact hazard.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $9377.00 · Current $6564.00 Reduced

General-duty citation text

29 CFR 1910.305(a)(2)(x): Flexible cords and cables shall be protected from accidental damage, as might be caused, for example, by sharp corners, projections, and doorways or other pinch points.    a. On or about May 7, 2019, the flexible cord electrical power supply for the Shaker Table was laid on the floor and run across a short peaked concrete wall then into the Shaker Table. The flexible cord passed over metal projections atop the peaked concrete wall, passed over the housing wall of the exterior of the Shaker Table and was subject to pinch points associated with the Shaker Table vibrational mechanisms without protection from damage. Due to this condition, employees have exposure to potential electrical contact hazards.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(a)(2)(xi): Cable assemblies and flexible cords and cables shall be supported in place at intervals that ensure that they will be protected from physical damage. Support shall be in the form of staples, cables ties, straps, or similar type fittings installed so as not to cause damage.    a. On or about May 7, 2019, the flexible cord electrical power supply for the Shaker Table was laid on the floor and run across a short peaked concrete wall then into the Shaker Table. The flexible cord was not supported to ensure protection from damage. Due to this condition, employees have exposure to potential electrical contact hazards.

Issued

2019-09-25 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

General-duty citation text

29 CFR 1910.305(b)(2)(i): All pull boxes, junction boxes, and fittings shall be provided with covers identified for the purpose. If metal covers are used, they shall be grounded. In completed installations, each outlet box shall have a cover, faceplate, or fixture canopy. Covers of outlet boxes having holes through which flexible cord pendants pass shall be provided with bushings designed for the purpose or shall have smooth, well-rounded surfaces on which the cords may bear.  a. On or about May 7, 2019, Shake-Out department employees were exposed to live electric parts due to the damaged electrical junction box for the Shake-Out Table electrical power supply located on a structural steel beam at the aisleway just east of the Shaker Table. The hinged cover for the enclosure was damaged and unable to close. Due to this condition, employees operating the Shaker Table controls which were located 3-4 inches below the open live parts were exposed to an electrical contact hazard.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $9377.00 · Current $6564.00 Reduced

General-duty citation text

29 CFR 1910.305(g)(2):  Identification, splices, and terminations.    29 CFR 1910.305(g)(2)(iii): Flexible cords and cables shall be connected to devices and fittings so that strain relief is provided that will prevent pull from being directly transmitted to joints or terminal screws.    a. On or about April 8, 2019, the strain relief device was damaged and pulled apart for the electrical power supply entering the motor housing junction box for the Rod Bending Machine in the Shake-out department. Due to this condition, the Rod Bending Machine Operator was exposed to an electrical contact hazard.

Issued

2019-09-25 00:00:00

Abate by

2020-10-30 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(c): Permissible exposure limit (PEL). The employer shall ensure that no employee is exposed to an airborne concentration of respirable crystalline silica in excess of 50 micrograms per cubic meter, calculated as an 8-hour TWA.  a. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator duties. The employee was exposed to a concentration of 100.78 micrograms per cubic meter as an 8-hour time weighted average during the 474 minute sampling period which was approximately 2.01 times the PEL. Zero exposure was assumed for the six minutes not sampled.    b. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Big Mill Operator duties. The employee was exposed to a concentration of 87.62 micrograms per cubic meter as an 8-hour time weighted average during the 478 minute sampling period which was approximately 1.75 times the PEL. Zero exposure was assumed for the two minutes not sampled.  c. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Trim Core Mill Operator duties. The employee was exposed to a concentration of 89.03 micrograms per cubic meter as an 8-hour time weighted average during the 473 minute sampling period which was approximately 1.78 times the PEL. Zero exposure was assumed for the seven minutes not sampled.  d. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Mill Operator Helper duties. The employee was exposed to a concentration of 122.22 micrograms per cubic meter as an 8-hour time weighted average during the 477 minute sampling period which was approximately 2.44 times the PEL. Zero exposure was assumed for the three minutes not sampled.  e. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator Helper duties. The employee was exposed to a concentration of 113.18 micrograms per cubic meter as an 8-hour time weighted average during the 442 minute sampling period which was approximately 2.26 times the PEL. Zero exposure was assumed for the 38 minutes not sampled.  f. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Flask Line Mill Operator duties. The employee was exposed to a concentration of 136.89 micrograms per cubic meter as an 8-hour time weighted average during the 471 minute sampling period which was approximately 2.74 times the PEL. Zero exposure was assumed for the nine minutes not sampled.  g. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Flask Line Mill Helper duties. The employee was exposed to a concentration of 75.53 micrograms per cubic meter as an 8-hour time weighted average during the 380 minute sampling period which was approximately 1.51 times the PEL. Zero exposure was assumed for the 100 minutes not sampled.  h. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Flask Line Mill Helper duties. The employee was exposed to a concentration of 95.93 micrograms per cubic meter as an 8-hour time weighted average during the 466 minute sampling period which was approximately 1.92 times the PEL. Zero exposure was assumed for the fourteen minutes not sampled.  i. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Chromite Room Mill Operator duties. The employee was exposed to a concentration of 71.53 micrograms per cubic meter as an 8-hour time weighted average during the 469 minute sampling period which was approximately 1.43 times the PEL. Zero exposure was assumed for the eleven minutes not sampled.  j. On or about May 7, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Bobcat Operator duties. The employee was exposed to a concentration of 200.4 micrograms per cubic meter as an 8-hour time weighted average during the 461 minute sampling period which was approximately 4.01 times the PEL. Zero exposure was assumed for the nineteen minutes not sampled.  k. On or about May 7, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Rod Bender Machine Operator duties. The employee was exposed to a concentration of 95.98 micrograms per cubic meter as an 8-hour time weighted average during the 461 minute sampling period which was approximately 1.92 times the PEL. Zero exposure was assumed for the nineteen minutes not sampled.  l. On or about May 7, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Float/Shaker Table Operator duties. The employee was exposed to a concentration of 112.93 micrograms per cubic meter as an 8-hour time weighted average during the 446 minute sampling period which was approximately 2.26 times the PEL. Zero exposure was assumed for the 34 minutes not sampled.  m. On or about May 7, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Forklift Operator duties. The employee was exposed to a concentration of 164.83 micrograms per cubic meter as an 8-hour time weighted average during the 468 minute sampling period which was approximately 3.29 times the PEL. Zero exposure was assumed for the twelve minutes not sampled.  n. On or about May 17, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator duties. The employee was exposed to a concentration of 132.53 micrograms per cubic meter as an 8-hour time weighted average during the 476 minute sampling period which was approximately 2.65 times the PEL. Zero exposure was assumed for the four minutes not sampled.  o. On or about May 17, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Closer duties. The employee was exposed to a concentration of 121.73 micrograms per cubic meter as an 8-hour time weighted average during the 470 minute sampling period which was approximately 2.43 times the PEL. Zero exposure was assumed for the ten minutes not sampled.  p. On or about May 17, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Clean-out duties. The employee was exposed to a concentration of 101.78 micrograms per cubic meter as an 8-hour time weighted average during the 457 minute sampling period which was approximately 2.04 times the PEL. Zero exposure was assumed for the 23 minutes not sampled.  q. On or about May 17, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mold Wash duties. The employee was exposed to a concentration of 158.75 micrograms per cubic meter as an 8-hour time weighted average during the 450 minute sampling period which was approximately 3.18 times the PEL. Zero exposure was assumed for the 30 minutes not sampled.  r. On or about May 17, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Roll Over Operator duties. The employee was exposed to a concentration of 99.86 micrograms per cubic meter as an 8-hour time weighted average during the 471 minute sampling period which was approximately 1.99 times the PEL. Zero exposure was assumed for the nine minutes not sampled.  s. On or about May 17, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator Helper duties. The employee was exposed to a concentration of 119.89 micrograms per cubic meter as an 8-hour time weighted average during the 474 minute sampling period which was approximately 2.39 times the PEL. Zero exposure was assumed for the six minutes not sampled.  t. On or about May 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Mill Operator Helper duties. The employee was exposed to a concentration of 58.23 micrograms per cubic meter as an 8-hour time weighted average during the 476 minute sampling period which was approximately 1.16 times the PEL. Zero exposure was assumed for the four minutes not sampled.  u. On or about May 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Set-up duties. The employee was exposed to a concentration of 92.61 micrograms per cubic meter as an 8-hour time weighted average during the 467 minute sampling period which was approximately 1.85 times the PEL. Zero exposure was assumed for the thirteen minutes not sampled.  v. On or about May 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Clean-out duties. The employee was exposed to a concentration of 61.48 micrograms per cubic meter as an 8-hour time weighted average during the 475 minute sampling period which was approximately 1.23 times the PEL. Zero exposure was assumed for the five minutes not sampled.  w. On or about May 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Mold Wash duties. The employee was exposed to a concentration of 100.41 micrograms per cubic meter as an 8-hour time weighted average during the 469 minute sampling period which was approximately 2.01 times the PEL. Zero exposure was assumed for the eleven minutes not sampled.  x. On or about May 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Core Setter duties. The employee was exposed to a concentration of 132.13 micrograms per cubic meter as an 8-hour time weighted average during the 466 minute sampling period which was approximately 2.64 times the PEL. Zero exposure was assumed for the fourteen minutes not sampled.  y. On or about May 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Core Setter duties. The employee was exposed to a concentration of 116.25 micrograms per cubic meter as an 8-hour time weighted average during the 462 minute sampling period which was approximately 2.32 times the PEL. Zero exposure was assumed for the eighteen minutes not sampled.  z. On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator Helper duties. The employee was exposed to a concentration of 98.35 micrograms per cubic meter as an 8-hour time weighted average during the 456 minute sampling period which was approximately 1.97 times the PEL. Zero exposure was assumed for the 24 minutes not sampled.  aa. On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Trim Core Mill Table/Numbers duties. The employee was exposed to a concentration of 69.70 micrograms per cubic meter as an 8-hour time weighted average during the 451 minute sampling period which was approximately 1.39 times the PEL. Zero exposure was assumed for the 29 minutes not sampled.  bb.  On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Trim Core Mill Operator duties. The employee was exposed to a concentration of 65.71 micrograms per cubic meter as an 8-hour time weighted average during the 466 minute sampling period which was approximately 1.31 times the PEL. Zero exposure was assumed for the fourteen minutes not sampled.  cc. On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Set-up duties. The employee was exposed to a concentration of 68.92 micrograms per cubic meter as an 8-hour time weighted average during the 476 minute sampling period which was approximately 1.38 times the PEL. Zero exposure was assumed for the four minutes not sampled.  dd.  On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Grey Flow Coat/Finisher duties. The employee was exposed to a concentration of 63.97 micrograms per cubic meter as an 8-hour time weighted average during the 473 minute sampling period which was approximately 1.28 times the PEL. Zero exposure was assumed for the seven minutes not sampled.  ee. On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Blue Flow Coat/Finisher duties. The employee was exposed to a concentration of 65.26 micrograms per cubic meter as an 8-hour time weighted average during the 468 minute sampling period which was approximately 1.31 times the PEL. Zero exposure was assumed for the twelve minutes not sampled.  ff. On or about June 6, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Crane Operator duties. The employee was exposed to a concentration of 61.05 micrograms per cubic meteras an 8-hour time weighted average during the 475 minute sampling period which was approximately 1.22 times the PEL. Zero exposure was assumed for the five minutes not sampled.    Silicosis and cancer are illnesses associated with exposure to airborne respirable crystalline silica.

Issued

2019-09-25 00:00:00

Abate by

2020-10-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(f)(1): Methods of compliance-(1) Engineering and work practice controls. 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.    The employer failed to implement engineering and work practice controls to assure employee exposure to respirable crystalline silica was below the permissible exposure limit.  Employees with exposure in excess of the PEL included, but is not limited to, the following documented employee exposures:    a. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator duties. The employee was exposed to a concentration of 100.78 micrograms per cubic meter as an 8-hour time weighted average during the 474 minute sampling period which was approximately 2.01 times the PEL. Zero exposure was assumed for the six minutes not sampled.      b. On or about April 30, 2019, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Big Mill Operator duties. The employee was exposed to a concentration of 87.62 micrograms per cubic meter as an 8-hour time weighted average during the 478 minute sampling period which was approximately 1.75 times the PEL. Zero exposure was assumed for the two minutes not sampled.    c. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Trim Core Mill Operator duties. The employee was exposed to a concentration of 89.03 micrograms per cubic meter as an 8-hour time weighted average during the 473 minute sampling period which was approximately 1.78 times the PEL. Zero exposure was assumed for the seven minutes not sampled.    d. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Mill Operator Helper duties. The employee was exposed to a concentration of 122.22 micrograms per cubic meter as an 8-hour time weighted average during the 477 minute sampling period which was approximately 2.44 times the PEL. Zero exposure was assumed for the three minutes not sampled.    e. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator Helper duties. The employee was exposed to a concentration of 113.18 micrograms per cubic meter as an 8-hour time weighted average during the 442 minute sampling period which was approximately 2.26 times the PEL. Zero exposure was assumed for the 38 minutes not sampled.    f. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Flask Line Mill Operator duties. The employee was exposed to a concentration of 136.89 micrograms per cubic meter as an 8-hour time weighted average during the 471 minute sampling period which was approximately 2.74 times the PEL. Zero exposure was assumed for the nine minutes not sampled.    g. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Flask Line Mill Helper duties. The employee was exposed to a concentration of 75.53 micrograms per cubic meter as an 8-hour time weighted average during the 380 minute sampling period which was approximately 1.51 times the PEL. Zero exposure was assumed for the 100 minutes not sampled.    h. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Flask Line Mill Helper duties. The employee was exposed to a concentration of 95.93 micrograms per cubic meter as an 8-hour time weighted average during the 466 minute sampling period which was approximately 1.92 times the PEL. Zero exposure was assumed for the fourteen minutes not sampled.    i. On or about April 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Chromite Room Mill Operator duties. The employee was exposed to a concentration of 71.53 micrograms per cubic meter as an 8-hour time weighted average during the 469 minute sampling period which was approximately 1.43 times the PEL. Zero exposure was assumed for the eleven minutes not sampled.    j. On or about May 7, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Bobcat Operator duties. The employee was exposed to a concentration of 200.4 micrograms per cubic meter as an 8-hour time weighted average during the 461 minute sampling period which was approximately 4.01 times the PEL. Zero exposure was assumed for the nineteen minutes not sampled.    k. On or about May 7, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Rod Bender Machine Operator duties. The employee was exposed to a concentration of 95.98 micrograms per cubic meter as an 8-hour time weighted average during the 461 minute sampling period which was approximately 1.92 times the PEL. Zero exposure was assumed for the nineteen minutes not sampled.    l. On or about May 7, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Float/Shaker Table Operator duties. The employee was exposed to a concentration of 112.93 micrograms per cubic meter as an 8-hour time weighted average during the 446 minute sampling period which was approximately 2.26 times the PEL. Zero exposure was assumed for the 34 minutes not sampled.    m. On or about May 7, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Shake-out Forklift Operator duties. The employee was exposed to a concentration of 164.83 micrograms per cubic meter as an 8-hour time weighted average during the 468 minute sampling period which was approximately 3.29 times the PEL. Zero exposure was assumed for the twelve minutes not sampled.    n. On or about May 17, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator duties. The employee was exposed to a concentration of 132.53 micrograms per cubic meter as an 8-hour time weighted average during the 476 minute sampling period which was approximately 2.65 times the PEL. Zero exposure was assumed for the four minutes not sampled.    o. On or about May 17, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Closer duties. The employee was exposed to a concentration of 121.73 micrograms per cubic meter as an 8-hour time weighted average during the 470 minute sampling period which was approximately 2.43 times the PEL. Zero exposure was assumed for the ten minutes not sampled.    p. On or about May 17, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Clean-out duties. The employee was exposed to a concentration of 101.78 micrograms per cubic meter as an 8-hour time weighted average during the 457 minute sampling period which was approximately 2.04 times the PEL. Zero exposure was assumed for the 23 minutes not sampled.    q. On or about May 17, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mold Wash duties. The employee was exposed to a concentration of 158.75 micrograms per cubic meter as an 8-hour time weighted average during the 450 minute sampling period which was approximately 3.18 times the PEL. Zero exposure was assumed for the 30 minutes not sampled.    r. On or about May 17, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Roll Over Operator duties. The employee was exposed to a concentration of 99.86 micrograms per cubic meter as an 8-hour time weighted average during the 471 minute sampling period which was approximately 1.99 times the PEL. Zero exposure was assumed for the nine minutes not sampled.    s. On or about May 17, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator Helper duties. The employee was exposed to a concentration of 119.89 micrograms per cubic meter as an 8-hour time weighted average during the 474 minute sampling period which was approximately 2.39 times the PEL. Zero exposure was assumed for the six minutes not sampled.    t. On or about May 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Mill Operator Helper duties. The employee was exposed to a concentration of 58.23 micrograms per cubic meter as an 8-hour time weighted average during the 476 minute sampling period which was approximately 1.16 times the PEL. Zero exposure was assumed for the four minutes not sampled.    u. On or about May 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Set-up duties. The employee was exposed to a concentration of 92.61 micrograms per cubic meter as an 8-hour time weighted average during the 467 minute sampling period which was approximately 1.85 times the PEL. Zero exposure was assumed for the thirteen minutes not sampled.    v. On or about May 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Clean-out duties. The employee was exposed to a concentration of 61.48 micrograms per cubic meter as an 8-hour time weighted average during the 475 minute sampling period which was approximately 1.23 times the PEL. Zero exposure was assumed for the five minutes not sampled.    w. On or about May 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Mold Wash duties. The employee was exposed to a concentration of 100.41 micrograms per cubic meter as an 8-hour time weighted average during the 469 minute sampling period which was approximately 2.01 times the PEL. Zero exposure was assumed for the eleven minutes not sampled.    x. On or about May 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Core Setter duties. The employee was exposed to a concentration of 132.13 micrograms per cubic meter as an 8-hour time weighted average during the 466 minute sampling period which was approximately 2.64 times the PEL. Zero exposure was assumed for the fourteen minutes not sampled.    y. On or about May 30, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Main Line Core Setter duties. The employee was exposed to a concentration of 116.25 micrograms per cubic meter as an 8-hour time weighted average during the 462 minute sampling period which was approximately 2.32 times the PEL. Zero exposure was assumed for the eighteen minutes not sampled.    z. On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing Loop Line Mill Operator Helper duties. The employee was exposed to a concentration of 98.35 micrograms per cubic meter as an 8-hour time weighted average during the 456 minute sampling period which was approximately 1.97 times the PEL. Zero exposure was assumed for the 24 minutes not sampled.    aa. On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Trim Core Mill Table/Numbers duties. The employee was exposed to a concentration of 69.70 micrograms per cubic meter as an 8-hour time weighted average during the 451 minute sampling period which was approximately 1.39 times the PEL. Zero exposure was assumed for the 29 minutes not sampled.    bb.  On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Trim Core Mill Operator duties. The employee was exposed to a concentration of 65.71 micrograms per cubic meter as an 8-hour time weighted average during the 466 minute sampling period which was approximately 1.31 times the PEL. Zero exposure was assumed for the fourteen minutes not sampled.    cc. On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Set-up duties. The employee was exposed to a concentration of 68.92 micrograms per cubic meter as an 8-hour time weighted average during the 476 minute sampling period which was approximately 1.38 times the PEL. Zero exposure was assumed for the four minutes not sampled.    dd.  On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Grey Flow Coat/Finisher duties. The employee was exposed to a concentration of 63.97 micrograms per cubic meter as an 8-hour time weighted average during the 473 minute sampling period which was approximately 1.28 times the PEL. Zero exposure was assumed for the seven minutes not sampled.    ee. On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Blue Flow Coat/Finisher duties. The employee was exposed to a concentration of 65.26 micrograms per cubic meter as an 8-hour time weighted average during the 468 minute sampling period which was approximately 1.31 times the PEL. Zero exposure was assumed for the twelve minutes not sampled.    ff. On or about June 6, an employee was exposed to airborne respirable crystalline silica that exceeded the PEL while performing South Core Room Crane Operator duties. The employee was exposed to a concentration of 61.05 micrograms per cubic meter as an 8-hour time weighted average during the 475 minute sampling period which was approximately 1.22 times the PEL. Zero exposure was assumed for the five minutes not sampled.      Silicosis and cancer are illnesses associated with exposure to airborne respirable crystalline silica.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(g)(1): Respiratory protection-(1) General. Where respiratory protection is required by this section, the employer must provide each employee an appropriate respirator that complies with the requirements of this paragraph and 29 CFR 1910.134. ?The employer failed to require respiratory protection and implement a respiratory protection program that complied with 29 CFR 1910.134 for employees with exposures that exceeded the permissible exposure limit (PEL) for respirable silica. Documented exposures included:    a. On April 30, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 12 instance a. for exposure information,)    b. On April 30, 2019, an employee in the South Core Room performing Big Mill Operator job duties (see Citation 1 item 12 instance b. for exposure information,)    c. On April 30, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 12 instance c. for exposure information,)    d. On April 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance d. for exposure information,)    e. On April 30, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance e. for exposure information,)    f.  On April 30, 2019, an employee in the Flask Line area performing Mill Operator job duties (see Citation 1 item 12 instance f. for exposure information,)    g. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance g. for exposure information,)    h. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance h. for exposure information,)    i. On April 30, 2019, an employee in the Chromite area performing Mill Operator job duties (see Citation 1 item 12 instance i. for exposure information,)    j. On May 7, 2019, an employee in the Shake-out area performing Bobcat Operator job duties (see Citation 1 item 12 instance j. for exposure information,)    k. On May 7, 2019, an employee in the Shake-out area performing Rob Bender Machine Operator job duties (see Citation 1 item 12 instance k. for exposure information,)     l. On May 7, 2019, an employee in the Shake-out area performing Float/Shaker Table job duties (see Citation 1 item 12 instance l. for exposure information,)    m. On May 7, 2019, an employee in the Shake-out area performing Forklift Operator job duties (see Citation 1 item 12 instance m. for exposure information,)    n. On May 17, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 12 instance n. for exposure information,)    o. On May 17, 2019, an employee in the Loop Line area performing Closer job duties (see Citation 1 item 12 instance o. for exposure information,)    p. On May 17, 2019, an employee in the Loop Line area performing Clean-out job duties (see Citation 1 item 12 instance p. for exposure information,)    q. On May 17, 2019, an employee in the Loop Line area performing Mold Wash job duties (see Citation 1 item 12 instance q. for exposure information,)    r. On May 17, 2019, an employee in the Loop Line area performing Roll Over Operator job duties (see Citation 1 item 12 instance r. for exposure information,)    s. On May 17, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance s. for exposure information,)    t. On May 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance t. for exposure information,)    u. On May 30, 2019, an employee in the Main Line area performing Set-up job duties (see Citation 1 item 12 instance u. for exposure information,)    v. On May 30, 2019, an employee in the Main Line area performing Clean-out job duties (see Citation 1 item 12 instance v. for exposure information,)    w. On May 30, 2019, an employee in the Main Line area performing Mold Wash job duties (see Citation 1 item 12 instance w. for exposure information,)    x. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 12 instance x. for exposure information,)    y. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 12 instance y. for exposure information,)    z. On June 6, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance z. for exposure information,)    aa. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Table/Number job duties (see Citation 1 item 12 instance aa. for exposure information,)    bb. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 12 instance bb. for exposure information,)    cc. On June 6, 2019, an employee in the South Core Room performing Set-up job duties (see Citation 1 item 12 instance cc. for exposure information,)    dd. On June 6, 2019, an employee in the South Core Room performing Grey Flow Coat/Finisher job duties (see Citation 1 item 12 instance dd. for exposure information,)    ee. On June 6, 2019, an employee in the South Core Room performing Blue Flow Coat/Finisher job duties (see Citation 1 item 12 instance ee. for exposure information,)    ff. On June 6, 2019, an employee in the South Core Room performing Crane Operator job duties (see Citation 1 item 12 instance ff. for exposure information.)

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(g)(1): Respiratory protection. General. Where respiratory protection is required by this section, the employer must provide each employee an appropriate respirator that complies with the requirements of this paragraph and 29 CFR 1910.134. Respiratory protection is required:     29 CFR 1910.1053(g)(1)(iv): During periods when the employee is in a regulated area.    On or about April 30, 2019, the employer failed to require respiratory protection use for employees who worked in regulated areas with silica exposure that exceeded the permissible exposure limit. Regulated areas and respiratory protection use was required due to the following documented employee exposures:      a. On April 30, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 12 instance a. for exposure information,)    b. On April 30, 2019, an employee in the South Core Room performing Big Mill Operator job duties (see Citation 1 item 12 instance b. for exposure information,)    c. On April 30, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 12 instance c. for exposure information,)    d. On April 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance d. for exposure information,)    e. On April 30, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance e. for exposure information,)    f.  On April 30, 2019, an employee in the Flask Line area performing Mill Operator job duties (see Citation 1 item 12 instance f. for exposure information,)    g. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance g. for exposure information,)    h. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance h. for exposure information,)    i. On April 30, 2019, an employee in the Chromite area performing Mill Operator job duties (see Citation 1 item 12 instance i. for exposure information,)    j. On May 7, 2019, an employee in the Shake-out area performing Bobcat Operator job duties (see Citation 1 item 12 instance j. for exposure information,)    k. On May 7, 2019, an employee in the Shake-out area performing Rob Bender Machine Operator job duties (see Citation 1 item 12 instance k. for exposure information,)     l. On May 7, 2019, an employee in the Shake-out area performing Float/Shaker Table job duties (see Citation 1 item 12 instance l. for exposure information,)    m. On May 7, 2019, an employee in the Shake-out area performing Forklift Operator job duties (see Citation 1 item 12 instance m. for exposure information,)    n. On May 17, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 12 instance n. for exposure information,)    o. On May 17, 2019, an employee in the Loop Line area performing Closer job duties (see Citation 1 item 12 instance o. for exposure information,)    p. On May 17, 2019, an employee in the Loop Line area performing Clean-out job duties (see Citation 1 item 12 instance p. for exposure information,)    q. On May 17, 2019, an employee in the Loop Line area performing Mold Wash job duties (see Citation 1 item 12 instance q. for exposure information,)    r. On May 17, 2019, an employee in the Loop Line area performing Roll Over Operator job duties (see Citation 1 item 12 instance r. for exposure information,)    s. On May 17, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance s. for exposure information,)    t. On May 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance t. for exposure information,)    u. On May 30, 2019, an employee in the Main Line area performing Set-up job duties (see Citation 1 item 12 instance u. for exposure information,)    v. On May 30, 2019, an employee in the Main Line area performing Clean-out job duties (see Citation 1 item 12 instance v. for exposure information,)    w. On May 30, 2019, an employee in the Main Line area performing Mold Wash job duties (see Citation 1 item 12 instance w. for exposure information,)    x. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 12 instance x. for exposure information,)    y. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 12 instance y. for exposure information,)    z. On June 6, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance z. for exposure information,)    aa. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Table/Number job duties (see Citation 1 item 12 instance aa. for exposure information,)    bb. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 12 instance bb. for exposure information,)    cc. On June 6, 2019, an employee in the South Core Room performing Set-up job duties (see Citation 1 item 12 instance cc. for exposure information,)    dd. On June 6, 2019, an employee in the South Core Room performing Grey Flow Coat/Finisher job duties (see Citation 1 item 12 instance dd. for exposure information,)    ee. On June 6, 2019, an employee in the South Core Room performing Blue Flow Coat/Finisher job duties (see Citation 1 item 12 instance ee. for exposure information,)    ff. On June 6, 2019, an employee in the South Core Room performing Crane Operator job duties (see Citation 1 item 12 instance ff. for exposure information.)    Due to the failure to require respiratory protection use as part of a respiratory protection program that complied with this part, employees were at increased risk for silicosis and lung cancer associated with the inhalation hazards associated with respirable quartz silica.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(d)(1): Exposure assessment-(1) General. The employer shall assess the exposure of each employee who is or may reasonably be expected to be exposed to respirable crystalline silica at or above the action level in accordance with either the performance option in paragraph (d)(2) or the scheduled monitoring option in paragraph (d)(3) of this section.   a. On or about April 8, 2019, the employer failed to perform an exposure assessment for all employees who performed the job tasks in work areas where exposure to respirable crystalline silica at or above the action level was reasonably expected. Employees performed the following job tasks/classifications without an exposure assessment required by this part that included, but were not limited to: Main Mill Line Helper, Main Mill Line Clean-out, Main Mill Line Flow Coat, Main Mill Line Set-up, Main Mill Line Core Setters, Loop Line Helper, Loop Line Set-up, Loop Line Roll Over Operator, Loop Line Clean Out, Loop Line Flow Coat, Loop Line Closer, Loop Line Set-up, South Core Room Set-up, South Core Room Crane, South Core Room Trim Core Numbers/Table, South Core Room Blue Flow Coat/Finisher, North Core Room Helper, North Core Room Lead, Shake-out Rod Machine Operator, Shake-out Bobcat Operator, Shake-out  Forklift Operator, Shake-out Float/Shaker Table Operator, Chromite Room Helper, Chromite Room Finisher and Maintenance.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(e)(1): Regulated areas-(1) Establishment. The employer shall establish a regulated area wherever an employee's exposure to airborne concentrations of respirable crystalline silica is, or can reasonably be expected to be, in excess of the PEL.  The employer failed to establish and implement regulated areas for employees with exposure that exceeded the respirable crystalline silica PEL for the following documented employee exposures:   a. On April 30, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 12 instance a. for exposure information,)  b. On April 30, 2019, an employee in the South Core Room performing Big Mill Operator job duties (see Citation 1 item 12 instance b. for exposure information,)  c. On April 30, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 12 instance c. for exposure information,)  d. On April 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance d. for exposure information,)  e. On April 30, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance e. for exposure information,)  f.  On April 30, 2019, an employee in the Flask Line area performing Mill Operator job duties (see Citation 1 item 12 instance f. for exposure information,)  g. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance g. for exposure information,)  h. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance h. for exposure information,)  i. On April 30, 2019, an employee in the Chromite area performing Mill Operator job duties (see Citation 1 item 12 instance i. for exposure information,)  j. On May 7, 2019, an employee in the Shake-out area performing Bobcat Operator job duties (see Citation 1 item 12 instance j. for exposure information,)  k. On May 7, 2019, an employee in the Shake-out area performing Rob Bender Machine Operator job duties (see Citation 1 item 12 instance k. for exposure information,)   l. On May 7, 2019, an employee in the Shake-out area performing Float/Shaker Table job duties (see Citation 1 item 12 instance l. for exposure information,)  m. On May 7, 2019, an employee in the Shake-out area performing Forklift Operator job duties (see Citation 1 item 12 instance m. for exposure information,)  n. On May 17, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 12 instance n. for exposure information,)  o. On May 17, 2019, an employee in the Loop Line area performing Closer job duties (see Citation 1 item 12 instance o. for exposure information,)  p. On May 17, 2019, an employee in the Loop Line area performing Clean-out job duties (see Citation 1 item 12 instance p. for exposure information,)  q. On May 17, 2019, an employee in the Loop Line area performing Mold Wash job duties (see Citation 1 item 12 instance q. for exposure information,)  r. On May 17, 2019, an employee in the Loop Line area performing Roll Over Operator job duties (see Citation 1 item 12 instance r. for exposure information,)  s. On May 17, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance s. for exposure information,)  t. On May 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance t. for exposure information,)  u. On May 30, 2019, an employee in the Main Line area performing Set-up job duties (see Citation 1 item 12 instance u. for exposure information,)  v. On May 30, 2019, an employee in the Main Line area performing Clean-out job duties (see Citation 1 item 12 instance v. for exposure information,)  w. On May 30, 2019, an employee in the Main Line area performing Mold Wash job duties (see Citation 1 item 12 instance w. for exposure information,)  x. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 12 instance x. for exposure information,)  y. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 12 instance y. for exposure information,)  z. On June 6, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 12 instance z. for exposure information,)  aa. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Table/Number job duties (see Citation 1 item 12 instance aa. for exposure information,)  bb. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 12 instance bb. for exposure information,)  cc. On June 6, 2019, an employee in the South Core Room performing Set-up job duties (see Citation 1 item 12 instance cc. for exposure information,)  dd. On June 6, 2019, an employee in the South Core Room performing Grey Flow Coat/Finisher job duties (see Citation 1 item 12 instance dd. for exposure information,)  ee. On June 6, 2019, an employee in the South Core Room performing Blue Flow Coat/Finisher job duties (see Citation 1 item 12 instance ee. for exposure information,)  ff. On June 6, 2019, an employee in the South Core Room performing Crane Operator job duties (see Citation 1 item 12 instance ff. for exposure information.)    Due to the failure to establish any regulated areas in the workplace, employees were at increased risk for silicosis and lung cancer created by the inhalation hazards associated with respirable quartz silica.  Due to the failure to establish any regulated areas in the workplace, employees were at increased risk for silicosis and lung cancer created by the inhalation hazards associated with respirable quartz silica.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(f):  Methods of compliance. -   29 CFR 1910.1053(f)(2)(i): Written exposure control plan. (i) The employer shall establish and implement a written exposure control plan that contains the elements found in 29 CFR 1910.1053(f)(2)(i)(A)-(C).  On or about April 8, 2019, the employer failed to establish and implement a written exposure control plan for the workplace. The employer did not have a written description of the tasks that involved exposure to respirable crystalline silica, a written description of the engineering controls, work practices, and respiratory protection used to limit exposure or a written description of housekeeping measures. Employees in coremaking, moldmaking and Shake-Out department activities were exposed on a daily basis to inhalation hazards associated with silica that included silicosis and lung cancer.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $9377.00 · Current $6564.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(h)(1): Housekeeping. (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.  a. On or about May 30, 2019, the employer allowed dry sweeping in the South Core Finishing area. A South Core Grey Flow Coat/Finisher was observed dry sweeping with an industrial push broom and generating visible dust from the sweeping. During this daily activity of dry sweeping sand, the employee had exposure to inhalation hazards associated with the respirable crystalline silica.

Issued

2019-09-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

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.  a. On or about April 30, 2019, a South Core Room employee was witnessed using compressed air to clean clothing. During this activity, no ventilation system was used. Due to this activity, the employee was exposed to inhalation hazards associated with airborne silica generated through use of compressed air.  b. On or about April 30, 2019, a South Core Room employee was witnessed using compressed air to clean a work table surface where "numbers" were made as part of Trim Core duties. During this activity, no ventilation system was used. Due to this activity, the employee was exposed to inhalation hazards associated with airborne silica generated through use of compressed air.  c. On or about April 30, 2019, a Loop Line employee was witnessed using compressed air to clean clothing. During this activity, no ventilation system was used. Due to this activity, the employee was exposed to inhalation hazards associated with airborne silica generated through use of compressed air.

Issued

2019-09-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(h)(2)(ii): 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 no alternative method is feasible.   a. On or about April 30, 2019, a South Core Room employee was witnessed using compressed air to clean clothing. During this activity, no ventilation system was used. Due to this activity, the employee was exposed to inhalation hazards associated with airborne silica generated through use of compressed air.  b. On or about April 30, 3029, a South Core Room employee was witnessed using compressed air to clean a work table surface where "numbers" were made as part of Trim Core duties. Due to this activity, the employee was exposed to inhalation hazards associated with airborne silica generated through use of compressed air.  c. On or about April 30, 2019, a Loop Line employee was witnessed using compressed air to clean clothing. During this activity, no ventilation system was used. Due to this activity, the employee was exposed to inhalation hazards associated with airborne silica generated through use of compressed air.

Issued

2019-09-25 00:00:00

Abate by

2019-11-29 00:00:00

Penalty

Initial $13127.00 · Current $9189.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(i)(1)(i): Medical surveillance-(1) General. (i) The employer shall 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.  The employer failed to implement a medical surveillance program for employees with the following documented exposures:  a. On April 30, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 1 instance a. for exposure information,)  b. On April 30, 2019, an employee in the South Core Room performing Big Mill Operator job duties (see Citation 1 item 1 instance b. for exposure information,)  c. On April 30, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 1 instance c. for exposure information,)  d. On April 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance d. for exposure information,)  e. On April 30, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance e. for exposure information,)  f.  On April 30, 2019, an employee in the Flask Line area performing Mill Operator job duties (see Citation 1 item 1 instance f. for exposure information,)  g. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance g. for exposure information,)  h. On April 30, 2019, an employee in the Flask Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance h. for exposure information,)  i. On April 30, 2019, an employee in the Chromite area performing Mill Operator job duties (see Citation 1 item 1 instance i. for exposure information,)  j. On May 7, 2019, an employee in the Shake-out area performing Bobcat Operator job duties (see Citation 1 item 1 instance j. for exposure information,)  k. On May 7, 2019, an employee in the Shake-out area performing Rob Bender Machine Operator job duties (see Citation 1 item 1 instance k. for exposure information,)   l. On May 7, 2019, an employee in the Shake-out area performing Float/Shaker Table job duties (see Citation 1 item 1 instance l. for exposure information,)  m. On May 7, 2019, an employee in the Shake-out area performing Forklift Operator job duties (see Citation 1 item 1 instance m. for exposure information,)  n. On May 17, 2019, an employee in the Loop Line area performing Mill Operator job duties (see Citation 1 item 1 instance n. for exposure information,)  o. On May 17, 2019, an employee in the Loop Line area performing Closer job duties (see Citation 1 item 1 instance o. for exposure information,)  p. On May 17, 2019, an employee in the Loop Line area performing Clean-out job duties (see Citation 1 item 1 instance p. for exposure information,)  q. On May 17, 2019, an employee in the Loop Line area performing Mold Wash job duties (see Citation 1 item 1 instance q. for exposure information,)  r. On May 17, 2019, an employee in the Loop Line area performing Roll Over Operator job duties (see Citation 1 item 1 instance r. for exposure information,)  s. On May 17, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance s. for exposure information,)  t. On May 30, 2019, an employee in the Main Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance t. for exposure information,)  u. On May 30, 2019, an employee in the Main Line area performing Set-up job duties (see Citation 1 item 1 instance u. for exposure information,)  v. On May 30, 2019, an employee in the Main Line area performing Clean-out job duties (see Citation 1 item 1 instance v. for exposure information,)  w. On May 30, 2019, an employee in the Main Line area performing Mold Wash job duties (see Citation 1 item 1 instance w. for exposure information,)  x. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 1 instance x. for exposure information,)  y. On May 30, 2019, an employee in the Main Line area performing Core Setter job duties (see Citation 1 item 1 instance y. for exposure information,)  z. On June 6, 2019, an employee in the Loop Line area performing Mill Operator Helper job duties (see Citation 1 item 1 instance z. for exposure information,)  aa. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Table/Number job duties (see Citation 1 item 1 instance aa. for exposure information,)  bb. On June 6, 2019, an employee in the South Core Room performing Trim Core Mill Operator job duties (see Citation 1 item 1 instance bb. for exposure information,)  cc. On June 6, 2019, an employee in the South Core Room performing Set-up job duties (see Citation 1 item 1 instance cc. for exposure information,)  dd. On June 6, 2019, an employee in the South Core Room performing Grey Flow Coat/Finisher job duties (see Citation 1 item 1 instance dd. for exposure information,)  ee. On June 6, 2019, an employee in the South Core Room performing Blue Flow Coat/Finisher job duties (see Citation 1 item 1 instance ee. for exposure information,)  ff. On June 6, 2019, an employee in the South Core Room performing Crane Operator job duties (see Citation 1 item 1 instance ff. for exposure information,)

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $9377.00 · Current $6564.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(j)(1): Communication of respirable crystalline silica hazards to employees-(1) Hazard communication. The employer shall include respirable crystalline silica in the program established to comply with the hazard communication standard (HCS) (29 CFR 1910.1200). The employer shall ensure that each employee has access to labels on containers of crystalline silica and safety data sheets, and is trained in accordance with the provisions of HCS and paragraph (j)(3) of this section. The employer shall ensure that at least the following hazards are addressed: Cancer, lung effects, immune system effects, and kidney effects.  a. On or about April 8, 2019, throughout the facility, containers of crystalline silica (sand hoppers, silos and other storage containers) were not labeled according to the hazard communication standard. The employer failed to inform employees with appropriate labeling regarding cancer, lung effects, immune system effects and kidney effects associated with occupational exposure to airborne silica.

Issued

2019-09-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(j): Communication of respirable crystalline silica hazards to employees-   29 CFR 1910.1053(j)(3): Employee information and training.   29 CFR 1910.1053(j)(3)(i): The employer shall ensure that each employee covered by this section can demonstrate knowledge and understanding of at least the following:   29 CFR 1910.1053(j)(3)(i)(D): The contents of this section;  On or about April 8, 2019, the employer failed to ensure that employees received training and information on the contents of the OSHA respirable crystalline silica standard, 29 CFR 1910.1053.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1200(f)(10): The employer shall ensure that workplace labels or other forms of warning are legible, in English, and prominently displayed on the container, or readily available in the work area throughout each work shift. Employers having employees who speak other languages may add the information in their language to the material presented, as long as the information is presented in English as well.  a. On or about April 8, 2019, throughout the facility, containers of crystalline silica (sand hoppers, silos and other storage containers) were not labeled according to the hazard communication standard. The employer failed to inform employees with appropriate labeling regarding cancer, lung effects, immune system effects and kidney effects associated with occupational exposure to airborne silica.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $26255.00 · Current $18379.00 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.132(a): Application. Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact.     a. On or about April 8, 2019, the employer failed to assure that employees involved with Flow Coat processes in the coremaking production areas were provided and required to use personal protective equipment and/or protective clothing to protect against thermal burns to the upper extremities. Employees were exposed to thermal hazards and had an increased risk for burns due to the lack of PPE or protective clothing when applying the flammable material and then igniting the applied material with a butane torch.    b. On or about April 8, 2019, the employer failed to assure that employees involved with Mold Wash processes in the moldmaking production areas were provided with and required to use personal protective equipment and/or protective clothing to protect against thermal burns to the upper extremities. Employees were exposed to thermal hazards and had an increased risk for burns due to the lack of PPE or protective clothing when applying the flammable material and then igniting the applied material with a butane torch.  Liberty Casting Company, LLC was previously cited for a violation of this Occupational Safety and Health Standard, which was contained in OSHA inspection number 1340635, citation number 1, item number 2a and was affirmed as a final order on December 4, 2018 with respect to a workplace located at 550 Liberty Road, Delaware, Ohio 43015.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 1560

General-duty citation text

29 CFR 1910.132(d): Hazard assessment and equipment selection.  29 CFR 1910.132(d)(1): The employer shall assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE). If such hazards are present, or likely to be present, the employer shall:  29 CFR 1910.132(d)(1)(i): Select, and have each affected employee use, the types of PPE that will protect the affected employee from the hazards identified in the hazard assessment;  a. On or about April 8, 2019, the employer failed to select and require the use of PPE for protection against burns associated with "Flow Coat" operations that involved the ignition of flammable liquids with butane torches as part of coremaking production processes. Due to this condition, employees have increased risk for burns during these activities.    b. On or about April 8, 2019, the employer failed to select and require the use of PPE for protection against burns associated with Mold Wash operations that involved the ignition of flammable liquids with butane torches as part of moldmaking production processes. Due to this condition, employees have increased risk for burns during these activities.  Liberty Casting Company, LLC was previously cited for a violation of this Occupational Safety and Health Standard, which was contained in OSHA inspection number 1340635, citation number 1, item number 2b and was affirmed as a final order on December 4, 2018 with respect to a workplace located at 550 Liberty Road, Delaware, Ohio 43015.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $26255.00 · Current $18379.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section.   a. On or about May 17, 2019, the employer failed to develop, implement and maintain documented machine specific lockout/tagout (control of hazardous energy) procedures for the Loop Line department that included the Roll-Over machine and the conveyor system. Employees performed activities covered by this part that included, but were not limited to, conveyor mechanical repairs. During covered activities, maintenance employees were exposed to caught-in hazards associated with the mechanical energy associated with the conveyor mechanism  Liberty Casting Company, LLC was previously cited for a violation of this Occupational Safety and Health Standard, which was contained in OSHA inspection number 1045810, citation number 1, item number 1 and was affirmed as a final order on May 20, 2015, with respect to a workplace located at 550 Liberty Road, Delaware, Ohio 43015.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(4):  Energy control procedure.  29 CFR 1910.147(c)(4)(ii): The procedures shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, the following:  29 CFR 1910.147(c)(4)(ii)(B): Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy;  a. On or about April 30, 2019, the employer failed to document the specific procedural steps for the control of potentially hazardous energy for the Loop Line Mill internal auger assembly. Employees performed required activities covered by this part that included cleaning material from the auger section to "unjam" material buildup. During these covered activities, the Loop Line Mill Operator and the Loop Line Mill Helper were exposed to caught-in hazards associated with the mechanical energy associated with the internal auger assembly.  Liberty Casting Company, LLC was previously cited for a violation of an equivalent Occupational Safety and Health Standard (1910.147(c)(4)(i)) which was contained in OSHA inspection number 1045810, citation number 1, item number 1 and was affirmed as a final order on May 20, 2015, with respect to a workplace located at 550 Liberty Road, Delaware, Ohio 43015.

Issued

2019-09-25 00:00:00

Abate by

2019-10-30 00:00:00

Penalty

Initial $26255.00 · Current $18379.00 Reduced

Hazardous substances 8870

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Each authorized employee shall receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control.  a. On or about April 30, an employee working as the Loop Line Helper performed duties covered by this part and had not received training in the hazardous energy sources related to the Loop Line Mill, the methods and means for hazardous energy isolation and the methods and means of hazardous energy control for the Loop Line Mill. The employee worked on the interior auger section of the Loop Line Mill with exposure to potential caught-in hazards associated with this equipment.    b. On or about May 17, 2019, a maintenance technician performed duties covered by this part and had not received training in the hazardous energy sources related to the Loop Line conveyor system, the methods and means for hazardous energy isolation and the methods and means of hazardous energy control for the Loop Line conveyor system. The employee worked on the conveyor system, removed machine guards to perform the required work and had exposure to caught-in hazards associated with the power transmission equipment associated with the conveyor.  Liberty Casting Company, LLC was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 1045810, citation number 1, item number 2 and was affirmed as a final order on May 20, 2015, with respect to a workplace located at 550 Liberty Road, Delaware, Ohio 43015.