OSHA Inspection: ALUDYNE COLUMBUS, LLC

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $13828.00 · Current $9680.00 Reduced

General-duty citation text

29 CFR  1910.133(a)(1): The employer did not ensure that each affected employee uses appropriate eye or face protection when exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation:  a) Core Shop Area; On or about August 10, 2023, and at times prior, employees were exposed to severe skin burns and eye damage, in that the employer did not ensure employees who work with Isofast 705 Catalyst DR400 and Alpha-Cleaner 9006 were provided personal protective equipment, such as but not limited to chemical goggles.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR  1910.138(a):The employer did not select and require employee(s) to use appropriate hand protection when employees' hands were exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasion; punctures; chemical burns; thermal burns; and harmful temperature extremes.  a) Core Shop Area; On or about August 10, 2023 and at times prior, employees were exposed to chemical hazards, in that the employer did not ensure employees who work with Isofast 705 Catalyst DR400 and  Alpha-Cleaner 9006 were not provided personal protective equipment, such as but not limited to chemical resistant gloves.

Issued

2024-01-16 00:00:00

Penalty

Initial $13828.00 · Current $9680.00 Reduced

General-duty citation text

29 CFR  1910.151(c):Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:  a) Core Shop Area: On or about August 10, 2023, and at times prior, employees were exposed to eye and skin corrosives, in that the employer did not ensure that the emergency eye wash station was available for immediate emergency use, in that a trash can was being stored in or around the station blocking access.   b) Core Shop Area: On or about August 10, 2023, and at times prior, employees were exposed to eye and skin corrosives, in that the employer did not ensure that the emergency eye wash station was available for immediate emergency use, in that the eyewash station was not kept clean and free of debris, causing additional hazards to the eyes if employees were to use.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $16131.00 · Current $11292.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(c):The employer did not ensure that no employee was exposed to an airborne concentration of respirable crystalline silica in excess of 50 ug/m3, calculated as an 8-hour TWA:  a) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to respirable crystalline silica hazards, in that the employer does not ensure employees are not exposed to an airborne concentration of respirable silica in excess of 50 ug/m3, calculated as an 8-hour TWA while an employee was hammering castings and was exposed to an 8-hour time-weighted average concentration of respirable crystalline silica at 150.0 micrograms per cubic meter of air (mcg/m), 2.99 times the permissible exposure limit (PEL) of 50 mcg/m. The sampling was performed during one shift on September 13, 2023 for 480 minutes.  b) Cell-19 Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to respirable crystalline silica hazards, in that the employer does not ensure employees are not exposed to an airborne concentration of respirable silica in excess of 50 ug/m3, calculated as an 8-hour TWA while an employee was hammering or inspecting castings and was exposed to an 8-hour time-weighted average concentration of respirable crystalline silica at 110.0 micrograms per cubic meter of air (mcg/m), 2.3 times the permissible exposure limit (PEL) of 50 mcg/m. The sampling was performed during one shift on September 13, 2023 for 480 minutes.  c) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to respirable crystalline silica hazards, in that the employer does not ensure employees are not exposed to an airborne concentration of respirable silica in excess of 50 ug/m3, calculated as an 8-hour TWA while an employee was  hammering castings and was exposed to an 8-hour time-weighted average concentration of respirable crystalline silica at 120.0 micrograms per cubic meter of air (mcg/m), 2.40 times the permissible exposure limit (PEL) of 50 mcg/m. The sampling was performed during one overnight shift from October 23-24, 2023 for 480 minutes.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(f)(1):The employer did not utilize engineering and work practice controls to reduce and maintain employee exposure to respirable crystalline silica to or below the PEL:  a) C/D Degating Area; the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 150.0 micrograms per cubic meter of air (mcg/m), or 2.99 times the permissible exposure limit (PEL) of 50 mcg/m. The sampling was performed during one shift on September 13, 2023, for 480 minutes. The employer did not ensure engineering and administrative controls reduced employee's exposure below the PEL.  b) Cell-19 Area; the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 110.0 micrograms per cubic meter of air (mcg/m), or 2.3 times the permissible exposure limit (PEL) of 50 mcg/m. The sampling was performed during one shift on September 13, 2023, for 480 minutes. The employer did not ensure engineering and administrative controls reduced employee's exposure below the PEL.  c) C/D Degating Area; the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 120.0 micrograms per cubic meter of air (mcg/m), or 2.40 times the permissible exposure limit (PEL) of 50 mcg/m.  The sampling was performed during one shift on September 13, 2023, for 480 minutes. The employer did not ensure engineering and administrative controls reduced employee's exposure below the PEL.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(g)(1)(iv): Respiratory protection was not provided during periods when the employee was in a regulated area:  a) Cell-19 Area; the employer exposed employees to an 8-hour time-weighted average concentration of respirable crystalline silica at 110.0 micrograms per cubic meter of air (mcg/m), 2.3 times the permissible exposure limit (PEL) of 50 mcg/m3 and did not required employees. The sampling was performed during one shift on September 13, 2023 for 480 minutes.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.134(d)(1)(ii): The employer did not select and use a NIOSH-certified respirator in compliance with the conditions of its certification:  a) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer exposed employees to silicosis hazards, in that the employer did not ensure employees were provided NIOSH approved respirators, as employees were hammering to separate mold castings while wearing KN95s (BRAND: ASA Safety Supply Folding Mask; S/N: GB 2626-2006).

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $6913.00 · Current $4839.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(d)(3)(iv): Where the most recent exposure monitoring indicated that employee exposures were above the PEL, the employer did not repeat such monitoring within three months of the most recent monitoring:  a) Cell 5 Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.20 milligrams per cubic meter of air (mg/m), 4 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 1, 2023 for 480 minutes. The exposure monitoring was not repeated.  b) Cell 25 Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.67 milligrams per cubic meter of air (mg/m), 13.4 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 1, 2023 for 480 minutes. The next exposure monitoring was repeated July 11, 2023 for 480 minutes.  c) Blast 2 Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.52 milligrams per cubic meter of air (mg/m), 10.4 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 1, 2023 for 480 minutes. The next exposure monitoring was repeated July 11, 2023 for 480 minutes.  d) Forklift 1 Operators Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.061 milligrams per cubic meter of air (mg/m), 1.2 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 1, 2023 for 480 minutes. The next exposure monitoring was repeated July 12, 2023 for 480 minutes.  e) F-Degate Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.21 milligrams per cubic meter of air (mg/m), 4.2 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 2, 2023 for 480 minutes. The exposure monitoring was not repeated.  f) E-Degate Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.78 milligrams per cubic meter of air (mg/m), 15.6 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 2, 2023 for 480 minutes. The next exposure monitoring was repeated July 12, 2023 for 480 minutes.  g) A-Degate Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 3.7 milligrams per cubic meter of air (mg/m), 74 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 2, 2023 for 480 minutes. The exposure monitoring was not repeated.  h) FL Degate Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 1.30 milligrams per cubic meter of air (mg/m), 26 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 2, 2023 for 480 minutes. The next exposure monitoring was repeated July 12, 2023 for 480 minutes.  i) Section 3 Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.16 milligrams per cubic meter of air (mg/m), 3.2 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 3, 2023 for 480 minutes. The next exposure monitoring was repeated July 13, 2023 for 480 minutes.  j) Refractory Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.21 milligrams per cubic meter of air (mg/m), 4.2 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 3, 2023 for 480 minutes. The next exposure monitoring was repeated July 13, 2023 for 480 minutes.  k) Scales Area; On or about August 10, 2023, and at times prior, the employer exposed an employee to an 8-hour time-weighted average concentration of respirable crystalline silica at 0.13 milligrams per cubic meter of air (mg/m), 2.6 times the permissible exposure limit (PEL) of 0.05 mg/m^3. The sampling was performed during one shift on March 3, 2023 for 480 minutes. The next exposure monitoring was repeated July 12, 2023 for 480 minutes.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $16131.00 · Current $11292.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(e)(2)(i):The employer did not demarcate regulated areas from the rest of the workplace in a manner that minimized the number of employees exposed to respirable crystalline silica within the regulated area:  a) Walkway Between Cell-19 Area and Kuka Line; On or about August 10, 2023, the employer exposed employees to respirable crystalline silica, in that the employer did not demarcate regulated areas from the rest of the walkways in a manner that minimized the number of employees exposed to respirable crystalline silica above the OSHA Permissible Exposure Limit (PEL).

Issued

2024-01-16 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(e)(2)(ii):The employer shall post signs at all entrances to regulated areas that bear the legend specified in paragraph (j)(2) of this section.  a) Entrance of Scale Area; On or about August 10, 2023, the employer exposed employees to respiratory hazards, in that the employer did not post signs at all entrances to the regulated respirable crystalline silica area.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $16131.00 · Current $11292.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(f)(2)(i): Written exposure control plan. (i) The employer did not establish and implement a written exposure control plan that contains at least the following elements:  a) C/D Degating Area; On or about August 10, 2023, the employer exposed employees to respiratory hazards, in that the employer did not implement a written exposure control plan that was written and reviewed by the employer.  b) Cell 19 Area; On or about August 10, 2023, the employer exposed employees to respiratory hazards, in that the employer did not implement a written exposure control plan that was written and reviewed by the employer.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $16131.00 · Current $11292.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(g)(2):Where respirator use was required by this section, the employer did not institute a respiratory protection program in accordance with 29 CFR 1910.134:  a) Cell 19 Area; On or about August 10, 2023, and at times prior, the employer did not institute a respiratory protection for employees required to wear a respirator while exposed to crystalline silica above the OSHA Permissible Exposure Limit (PEL).  b) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer did not institute a respiratory protection for employees required to wear a respirator while exposed to crystalline silica above the OSHA Permissible Exposure Limit (PEL).

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:  a) Cell-19 Area; On or about August 10, 2023, and at times prior, the employer did not provide medical evaluation to employees required to wear a respirator while exposed to crystalline silica above the OSHA Permissible Exposure Limit (PEL).  b) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer did not provide medical evaluation to employees required to wear a respirator while exposed to crystalline silica above the OSHA Permissible Exposure Limit (PEL).

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR 1910.134(f)(2): The employer shall ensure that an employee using a tight-fitting facepiece respirator is fit tested prior to initial use of the respirator, whenever a different respirator facepiece (size, style, model or make) is used, and at least annually thereafter.  a) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer exposed employees to health hazards, in that the employer did not provide fit testing to employees who are required to wear a N95 respirators for employees who work in and around crystalline respirable silica.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $13828.00 · Current $9680.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(h)(1): The employer allowed dry sweeping or dry brushing where such activity could contribute to employee exposure to respirable crystalline silica and wet sweeping, HEPA-filtered vacuuming or other methods that minimize the likelihood of exposure were feasible:  a) Between Shipping and Finishing Area; On or about August 10, 2023, and at times prior, the employer exposed employees to respirable crystalline silica, in that employees were allowed to broom to clean dust from the floors.  b) Throughout the facility; On or about August 10, 2023, and at times prior, the employer exposed employees to respirable crystalline silica, in that the POWERBOSS and TENNANT 800 Sweepers an employee used to clean dust did not contain methods that  minimized the likelihood of exposure to crystalline silica.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $16131.00 · Current $11292.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(i)(1)(i): The employer did not make medical surveillance available at no cost to each employee, and at a reasonable time and place, for each employee who has been occupationally exposed to respirable crystalline silica at or above the action level for 30 or more days per year:   a) Cell-19 Area; On or about August 10, 2023, and at times prior, the employer exposed employees were exposed to respirable crystalline silica above OSHA permissible exposure limit of 50 mcg/m^3 for more than 30 days a year and the employer did not make available initial medical examinations for employees who inspect and hammer off the castings on automotive parts.  b) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer exposed employees were exposed to respirable crystalline silica above OSHA permissible exposure limit of 50 mcg/m^3 for more than 30 days a year and the employer did not make available initial medical examinations for employees who hammer off the castings on automotive parts.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(i)(3): The employer did not make available medical examinations that include the procedures described in paragraph (i)(2) of this section (except paragraph (i)(2)(v)) at least every three years, or more frequently if recommended by the PLHCP:  a) Cell-19 Area; On or about August 10, 2023, and at times prior, the employer exposed employees to respiratory hazards, in that the employer has not provided or made available periodic medical examinations to employees who inspect and hammer off the castings on automotive parts.  b) C/D Degating Area; On or about August 10, 2023, and at times prior, the employer exposed employees to respiratory hazards, in that the employer has not provided or made available periodic medical examinations to employees  who hammer off the castings on automotive parts.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $13828.00 · Current $9680.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(j)(3)(i): The employer did not ensure that each employee covered by this section could demonstrate knowledge and understanding of the following: (A) the health hazards associated with exposure to respirable crystalline silica; (B) specific tasks in the workplace that could result in exposure to respirable crystalline silica; (C) specific measures the employer has implemented to protect employees from exposure to respirable crystalline silica, including engineering controls, work practices, and respirators to be used; (D) the contents of this section; and, (E) the purpose and a description of the medical surveillance program required by paragraph (i) of this section:  a) Cell-19 Area; On or about August 10, 2023, employees were exposed to respiratory hazards, in that the employer did not ensure employees can demonstrate knowledge and understanding of health hazards, engineering controls, and work practices associated with respirable crystalline silica.  b) C/D Degating Area; On or about August 10, 2023, employees were exposed to respiratory hazards, in that the employer did not ensure employees can demonstrate knowledge and understanding of health hazards, engineering controls, and work practices associated with respirable crystalline silica.

Issued

2024-01-16 00:00:00

Penalty

Initial $1294.00 · Current $906.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(d)(6)(i):Within 15 working days after completing an exposure assessment in accordance with paragraph (d) of this section, the employer did not individually notify each affected employee in writing of the results of that assessment or post the results in an appropriate location accessible to all affected employees:  a) On or about August 10, 2023; the employer conducted an exposure assessment on March 1-3, 2023 that indicated employees were exposed to respirable crystalline silica above the OSHA PEL, and the employer had not notified employees of the results within 15 days of completing the assessment.  b) On or about August 10, 2023; the employer conducted an exposure assessment on July 11-13, 2023 that indicated employees were exposed to respirable crystalline silica above the OSHA PEL, and the employer had not notified employees of the results within 15 days of completing the assessment.

Issued

2024-01-16 00:00:00

Abate by

2024-02-13 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(k)(1)(ii)(F):Exposure measurement records taken by the employer to assess employee exposure to respirable crystalline silica did not contain the type of personal protective equipment, such as respirators, worn by the employees monitored:  a) Cell 4, Cell 19, Cell 6, Cell 24, Blast 2 area, C/D/E Degate areas, Shipping Scales, and Refractory areas; On or about August 10, 2023, the employer assess employees exposure to respirable crystalline silica during a monitoring event that took place July 11-12, 2023, and the exposure assessment records did not contained the type of personal protective equipment worn by the employees monitored.

Issued

2024-01-16 00:00:00

Penalty

Initial $1294.00 · Current $906.00 Reduced

General-duty citation text

29 CFR  1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:  a) Core Shop Area; On or about August 10, 2023, and at times prior, the employer exposed the employee to chemical hazards, in that the employer did not implement or provide training in regard to a written hazard communication program to discuss the information regarding  Isofast 705 Catalyst DR400 and Alpha-Cleaner 9006 that are used on a daily basis by employees.