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Inspection Detail
Note: The following inspection has not been indicated as closed. OSHA citation items will be posted 30 (thirty) days after the employer receives the citation(s), except in cases of significant public interest. Posted citation items reflect any amendments to citations that are the result of a prompt settlement, which OSHA encourages. Employers and employee representatives will continue to receive copies of the citation(s) upon issuance.
Inspection: 1753720.015 - Caterpillar Inc.
Inspection Information - Office: Peoria Area Office
Site Address:
Caterpillar Inc.
8826 Us-24
Mapleton, IL 61547
Mailing Address:
8826 Us-24, Mapleton, IL 61547
Union Status: Union
SIC:
NAICS: 331511/Iron Foundries
Inspection Type: Fat/Cat
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 11/14/2024
Emphasis:
Case Closed:
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 2170965 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 2 | 2 | ||||
| Current Violations | 2 | 2 | ||||
| Initial Penalty | $32,262 | $0 | $0 | $0 | $0 | $32,262 |
| Current Penalty | $32,262 | $0 | $0 | $0 | $0 | $32,262 |
| FTA Penalty | $0 | $0 | $0 | $0 | $0 | $0 |
| # | Citation ID | Citation Type | Standard Cited | Issuance Date | Abatement Due Date | Current Penalty | Initial Penalty | FTA Penalty | Contest | Latest Event | Note |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1. | 01001 | Serious | 19100028 B01 I | 12/02/2024 | $16,131 | $16,131 | $0 | 12/23/2024 | C - Contested | ||
| 2. | 02001 | Serious | 5A0001 | 12/02/2024 | 01/02/2025 | $16,131 | $16,131 | $0 | 12/23/2024 | C - Contested |
Investigation Summary
At 4:53 p.m. on June 6, 2024, an employee working as a molding machine operator for an iron foundry was operating the pour car located on Line 4/Department 437. The pour car is a cab operated trolley crane suspended from a monorail beam. The crane portion raises and lowers a pour ladle to pour molten iron into precast molds. The pour ladle holds a maximum of two tons of molten iron. Once filled, the pour car moves on monorail to a position to pour molten iron into molds. The pour car is filled by a storage vessel or holder. The Line 4 pour car can be filled from ether Holder #7 or #8. Holders #7 and #8 can hold a maximum of 50 tons of molten iron each. Holders #7 and #8 are tilted with a hydraulic cylinder to pour molten iron from the holder into pour car ladle. The molten iron exits the holder through a 9-inch-wide spout and pours into the pour car ladle. The process of pouring molten iron from a holder into the pour car ladle is referred to as "tap out." The employee positioned the pour car to tap out from Holder #8 and activated the hydraulic cylinder. The employee continued to tilt Holder #8 as a flow of iron from the holder had not occurred. A spout blockage released, and molten iron flowed uncontrolled from the pour car and onto the floor. A subsequent fire ensued which engulfed the pour car. The employee died due to multiple burns from contact with the molten iron and subsequent fire.
Keywords: Burn, Casting, Clogged, Contact, Engulfed, Fire, Foundry, Heat, High Temperature, Inexperience, Insufficient Supervision, Iron, Ladle, Machine operator, Material Handling, Misjudgment, Misjudgment of Hazardous Situation, Molding Machine, Molten Metal, Pouring, Skin, Struck By
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 1753720.015 | 28 | M | Fatality | Molding and casting machine operators |