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Occupational Safety and Health Administration OSHA

Violation Detail

Standard Cited: 5A0001 OSH Act General Duty Paragraph

Violation Items

Nr: 304038193 Citation: 01001A Issuance: 05/02/2001 ReportingID: 0627100

Viol Type:Serious NrInstances:1 Contest Date:
Abatement Date:05/08/2001 X Nr Exposed:32 Final Order:
Initial Penalty: $2,625.00 REC:A Emphasis:
Current Penalty: $1,500.00 Gravity:05 Haz Category:BURNS

Penalty and Failure to Abate Event History
Type Event Date Penalty Abatement Type FTA Insp
Penalty Z: Issued 05/02/2001 $2,625.00 05/08/2001 Serious  
Penalty I: Informal Settlement 05/24/2001 $1,500.00 05/08/2001 Serious  

Text For Citation: 01 Item/Group: 001A Hazard: BURNS

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to : In the Casting Department, employees were exposed to the hazards of molten metal explosions while performing casting operations. On or about December 22, 2000, molten copper metal exploded out of mold number six in the east casting machine during casting start-up. The explosion resulted in the injury of two employees working in the casting pit/hole and two employees on the floor level above the casting furnace. The employer failed to fully identify, evaluate and/or control known hazards associated with the casting process. Among others methods, feasible means of abatement include but are not limited to: 1. Install and/or use accurate temperature monitoring devices to monitor the pour temperature of the molten copper during start-up procedures. 2. Install shields or barriers that more effectively protect employees. Such barriers should be provided to protect employees working in the casting pit/hole, as well as employees walking/working on the main floor level above the casting furnace. 3. Further upgrade and/or automate the casting process by considering other casting techniques and state of the art technology. 4. Evaluate the possibility of reworking the current system to allow independent control of each platen assembly/mold cup to allow the casting crew to completely shut down a troublesome spout and mold without a shut-down of the entire process. 5. Increase the distance of the employees from the casting machine during pouring. Evaluate the use of an automatic leveling system which could be controlled from a distance. Metering pins could be controlled by motor control, or by some other remotely controlled device. 6.Increase employee distance from the launder and molds during all phases of the start-up and set-up processes to the extent feasible. 7.Conduct a comprehensive failure analysis of the casting operation, and develop comprehensive protocols which address each and every failure scenario. Then train exposed employees on the protocols. 8. Complete the development and implementation of a comprehensive training program for all employees working in the casting area. The training should be accomplished in a manner that assures information is conveyed at the level of understanding of exposed employees. A detailed training video, structured on- the-job training, computer based training programs and periodic refresher courses should be considered and/or completed and implemented. 9. Prohibit employees from "rodding out" a clogged spout during the pouring process. In the event that rodding or burning out spouts is necessary during the pouring process, bent rods with long handles could be provided, allowing employees to stand away from the launder during the rodding/burning process. 10. Require all employees in the casting pit/hole and on the main floor level above the casting furnace to don full personal protective gear including but not limited to aluminized coats and leggings, metatarsal guards, casting gloves, and helmets with full aluminized hoods during all phases of the casting process where the potential of a molten metal explosion or "blow-up" exists (especially during change-overs/set-ups and start-ups). The employer is not limited to any of the abatement methods recommended by OSHA, but may use any method that renders its work place free of the hazard. It is possible that some of the recommended methods may not be effective in all circumstances.

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