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Inspection Detail
Inspection: 123993784 - Dalton Foundries
Inspection Information - Office: Indiana Department Of Labor
Site Address:
Dalton Foundries
1900 East Jefferson
Warsaw, IN 46581
Mailing Address:
, , 00000
Union Status: Union
SIC:3321
NAICS: 0
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 11/09/1995
Planning Guide: Safety-Manufacturing
Emphasis:
Case Closed: 05/13/1996
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 361309370 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 6 | 1 | 4 | 11 | ||
| Current Violations | 4 | 1 | 5 | 10 | ||
| Initial Penalty | $23,500 | $35,000 | $0 | $0 | $0 | $58,500 |
| Current Penalty | $10,125 | $26,250 | $0 | $0 | $0 | $36,375 |
| FTA Penalty | $0 | $0 | $0 | $0 | $0 | $0 |
| # | Citation ID | Citaton Type | Standard Cited | Issuance Date | Abatement Due Date | Current Penalty | Initial Penalty | FTA Penalty | Contest | Latest Event | Note |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1. | 01001 | Serious | 2200080101 | 12/05/1995 | 12/23/1995 | $0 | $5,000 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 2. | 01002 | Other | 2200080101 | 12/05/1995 | 12/23/1995 | $0 | $5,000 | $0 | I - Informal Settlement | ||
| 3. | 01003 | Serious | 2200080101 | 12/05/1995 | 12/23/1995 | $2,625 | $3,500 | $0 | I - Informal Settlement | ||
| 4. | 01004 | Serious | 19100023 C01 | 12/05/1995 | 12/08/1995 | $3,750 | $5,000 | $0 | I - Informal Settlement | ||
| 5. | 01005 | Serious | 19100038 A05 III | 12/05/1995 | 12/23/1995 | $1,875 | $2,500 | $0 | I - Informal Settlement | ||
| 6. | 01006A | Serious | 19100179 B06 II | 12/05/1995 | 12/23/1995 | $1,875 | $2,500 | $0 | I - Informal Settlement | ||
| 7. | 01006B | Serious | 19100179 F06 III | 12/05/1995 | 12/23/1995 | $0 | $0 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 8. | 02001 | Willful | 2200080101 | 12/05/1995 | 12/08/1995 | $26,250 | $35,000 | $0 | I - Informal Settlement | ||
| 9. | 03001 | Other | 19100132 A | 12/05/1995 | 12/23/1995 | $0 | $0 | $0 | - | ||
| 10. | 03002 | Other | 19100165 B01 | 12/05/1995 | 12/23/1995 | $0 | $0 | $0 | - | ||
| 11. | 03003 | Other | 19100176 B | 12/05/1995 | 05/10/1996 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 12. | 03004 | Other | 19100303 F | 12/05/1995 | 12/08/1995 | $0 | $0 | $0 | - |
Investigation Summary
On or about June 22, 1995, iron from the cupola was being melted in the melting department of the Dalton Foundry and transferred by troughs to holding furnaces. The last section of these troughs was water-cooled and fed the holding furnace. Iron was being put into the #2 holding furnace. At approximately 2:41 a.m., a hole developed in the water-cooled nozzle section of the trough system that fed iron into the #2 furnace. The water became entrapped under the iron, and at approximately 2:45 a.m. it created an explosion. This explosion caused iron to fly out of the furnace and start several fires. Within 1 minute, another explosion occurred, sending more iron out of the furnace. Some employees thought there would be no more explosions and went into the work area to put out the fires. Another, larger explosion occurred that sent out a large amount of molten iron. Employees #1, #2, and #3 were killed. Employees #4 through #17 were injured. Four of them were hospitalized.
Keywords: BURN, FURNACE, WORK RULES, EQUIPMENT FAILURE, CLOGGED, EXPLOSION, MOLTEN METAL, IRON, FLYING OBJECT, FOUNDRY
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 123993784 | Fatality | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 2 | 123993784 | Non Hospitalized injury | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 3 | 123993784 | Non Hospitalized injury | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 4 | 123993784 | Hospitalized injury | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 5 | 123993784 | Non Hospitalized injury | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 6 | 123993784 | Non Hospitalized injury | Bruise/Contus/Abras | Occupation not reported | ||
| 7 | 123993784 | Non Hospitalized injury | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 8 | 123993784 | Non Hospitalized injury | Bruise/Contus/Abras | Molding and casting machine operators | ||
| 9 | 123993784 | Non Hospitalized injury | Bruise/Contus/Abras | Occupation not reported | ||
| 10 | 123993784 | Non Hospitalized injury | Bruise/Contus/Abras | Occupation not reported | ||
| 11 | 123993784 | Hospitalized injury | Burn/Scald(Heat) | Occupation not reported | ||
| 12 | 123993784 | Non Hospitalized injury | Bruise/Contus/Abras | Occupation not reported | ||
| 13 | 123993784 | Non Hospitalized injury | Bruise/Contus/Abras | Occupation not reported | ||
| 14 | 123993784 | Hospitalized injury | Burn/Scald(Heat) | Occupation not reported | ||
| 15 | 123993784 | Fatality | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 16 | 123993784 | Fatality | Burn/Scald(Heat) | Molding and casting machine operators | ||
| 17 | 123993784 | Hospitalized injury | Burn/Scald(Heat) | Molding and casting machine operators |