In 2008, over twelve metalcasting facilities have been fined so far this year for over $100,000 in safety and health citations.  Some of the facilities that were cited are located in the state of Ohio and were chosen for inspection as part of a local emphasis program (LEP) concentrating on the primary metal industry.

Following a series of fatalities and serious injuries in the metals industry, the state of Ohio has developed a comprehensive inspection program. The following types of metacasting facilities are part of the Ohio LEP primary inspection list:  grey & ductile iron (3321), malleable iron (3322), steel (3325) and aluminum (3365). Copper facilities (3366) and non-ferrous facilities (3369) except aluminum are placed on the secondary inspection list.

According to Ohio OSHA, manufacturing fatalities accounted for 32 percent of all fatalities in that state.  The program is intended to address hazards or industries that pose a particular risk to workers.  The inspections will address at a minimum the following safety and health issues:

• Material handling and storage, including but not limited to cranes, forklifts and rail yards;
• Control of hazardous energy (such as lockout/tagout);
• Machine guarding;
•  Hazard assessments, including use of PPE, fire explosion hazards associated with molten metal and emergency action plans;
• Air Contaminants (41);
• Review of all safety and health programs; 
• Ergonomic hazards.

Metalcasting Facilities also have been cited with large fines in New York, Illinois and Texas. Here is a sample of some of the serious violations and repeat violations that foundries are being cited for: 

• Lead and silica over-exposures;
• High-level noise exposure;
• Electrical hazards;
• Training deficiencies (including respiratory protection training);
• Lack of personal protective equipment for employees.

Federal OSHA is in the process of developing a National Emphasis Program (NEP) for primary metal, which would include metalcasting facilities. The NEP for primary metal will be released in 2009 during a new Administration.

Again, whether your metalcasting facility is small or large, it is critically important to be in compliance with current OSHA federal standards and regulations. Fore more information concerning safety and health compliance issues, contact Fred Kohloff, AFS Director of Environmental, Health & Safety at 800/537-4237.

In addition, OSHA offers free and confidential advice to small and medium-sized businesses in all states across the country through its On-Site Consultation Service, with priority given to high-hazard worksites. Consultation services are totally separate from enforcement and do not result in penalties or citations. If you have any questions regarding the LEP or NEP, contact Stephanie Salmon, AFS Washington Office at 202/842-4864 or This e-mail address is being protected from spam bots, you need JavaScript enabled to view it .