30th Environmental, Health, and Safety Conference

Cleveland Marriott East
October 9-11, 2018


Once a year for 30 years, the AFS Environmental, Health and Safety Division gathers together to hear from some of the most accomplished professionals in the field to:

  • Network
  • Discuss the issues of the day
  • Present the results of EHS research papers
  • Mingle with vendors showing off the newest equipment
  • Acknowledge those companies and individuals who have achieved significant safety goals

Please save the date and come join in the fun!
Please bring your laptop computer. Electronic connection to PowerPoint presentations, a speaker list, participant list, vendor list and local restaurant list will be provided on-site for your viewing during the conference.


  • Cleveland Marriott East
  • Warrensville Heights, Ohio
  • October 9-11, 2018
Get Directions

Hotel Information

  • Cleveland Marriott East
  • Warrensville Heights, Ohio
  • $145/night

Group Name: AFS Advanced Air Seminar and EHS Conference

Room Block Release Date: September 21, 2018

Reservations must be received on or before 12:00 p.m. on September 21. At the cutoff the hotel will review the reservation pickup and release any unreserved rooms for general sale. Room reservations made after the cutoff date will be made on a space- and rate-available basis at the AFS group rate after this date.

Parking: Complimentary on-site parking.

The Hotel is expecting to sell out as October is their busiest month.  Please make your hotel reservations as soon as possible.

Travel Information

Airport/Hotel Transportation:

Cleveland Hopkins International Airport (CLE) http://www.clevelandairport.com/

The Cleveland Marriott East does not provide shuttle service.

Estimated taxi fare: 45 USD (one way) / Hotel direction: 21 miles E

Driving Directions:

I-480 East to I-271 North. Exit 28B / Harvard Rd. Turn left at end of ramp. Hotel on left.

Rental Cars:

CLE has a consolidated rental car facility located off the airport grounds. Shuttle service is available for all rental car customers from the main terminal to the rental car facility. The rental car shuttle departs from the rental car shuttle door across from baggage claim 7. Rental car shuttles return customers to door 4 on arrivals level. Travelers can utilize the 2 banks of elevators across from the welcome center or escalators by claim 9 and claim 3 to access the departures level. For travelers needing assistance, a telephone center with rental car information is located at the info counter at Baggage Claim.

The shuttle bus ride from the terminal to the rental car facility takes approximately 5-7 minutes. The shuttle buses run continuously 24 hours a day, 7 days a week, 365 days a year.

The rental car facility is located at: 19601 Maplewood Avenue, Cleveland, OH 44135

Conference Agenda

Tuesday, October 9, 2018
7 a.m. – 3:45 p.m.
Conference Registration
7 – 8 a.m.
Continental Breakfast
8 – 8:30 a.m.
Welcome / Announcements / Introduction

Welcome / Announcements

Dan Oman, Haley & Aldrich Inc. | AFS EHS Division Chair


  • AFS EHS Committee Overview
  • Recognition of AFS EHS Division Members in Attendance
  • Conference Co-Chairs
8:30 – 9:15 a.m.
U.S. EPA's Policy Presentation

Speaker TBA

  • Policy priorities for U.S. EPA
  • Meeting current environmental challenges
  • Environmental challenges on the horizon
9:15 – 10 a.m.
The Benefits of the Smart Sectors Program for EPA and the Metalcasting Industry

Daisy Letendre, EPA Smart Sectors Program

  • Provide a summary of EPA’s Smart Sectors Program and some of its recent activities
  • Identify opportunities for the metalcasting industry to work cooperatively with EPA as part of the Smart Sectors Program
10 – 10:15 a.m.
Refreshment Break
10:15 – 11:15 a.m.
Foundry Solutions for Stormwater Cases

Moderator: Greg Kramer, ME Elecmetal  | IN                

Panelists:    Holly Hurst, David J. Joseph Co. | UT                

                     Dan Plant, Metal Technologies Inc. | IN 
                     David Georgeson, McWane Ductile | UT 

Improved stormwater quality through the use of hidden resources. BMP(s) originate from decommissioned area(s).

11:15 a.m. – Noon
Residual Risk and Technology Review (RTR) of Iron and Steel Foundry NESHAP for Major Sources

Phil Mulrine, EPA Office of Air and Radiation

  • EPA is required to complete a residual risk and technology review of its NESHAP rule for iron and steel foundry major sources by June 2020 (with a proposed rule by April 2019)
  • Provide an update on EPA’s rulemaking process and its efforts in working with the metalcasting industry on this rule
Noon – 1 p.m.
1 – 1:45 p.m.
State Air Toxics

Travis Quarles, ESCO Corporation  | OR 
Some states are promulgating rules governing emissions of air toxics that go well beyond EPA’s NESHAP requirements. The speakers will describe rules affecting foundries in two states – Oregon’s “Cleaner Air Oregon” rule and California’s rules specific to foundries, metals and risk assessment/ambient air monitoring.

1:45 – 2:30 p.m.
Stack Testing Procedures

Jim Schifo, Keramida Inc. | IN
Dan Plant, Metal Technologies Inc. | IN 

Learn the EPA requirements for stack testing procedures with a focus on PM2.5.

2:30 – 2:45 p.m.
Refreshment Break
2:45 – 3:45 p.m.
Creating Postive Working Relationships with Advocacy Groups

Moderator:   Mike Lenahan, Covia | MI
Panelists:     John Kurtz, Kurtz Bros. Inc. | OH
                      Derek Schafer, West Creek Conservancy | OH
                      Kurt Princic, Ohio EPA Northeast-District Office | OH
Learn from experts about what works and what doesn’t work when interacting with environmental advocacy groups, localresidents, and concerned citizens.

3:45 – 4:30 p.m.
Rust Spotting

Jeet Radia, McWane Inc. | AL 
Damage to paint on vehicle surfaces (rust spotting) in the vicinity of metalcasting facilities is a longstanding issue for many foundries. Rust spotting typically occurs when fine metallic particles deposit on and adhere to vehicle surfaces under the right conditions. When the particles rust, they stain the paint and give the appearance of rust spots. Foundries are often blamed for rust spotting even when other industrial sources in the neighborhood are partly or fully culpable. The speakers will outline the main causes of rust spotting, investigation techniques, common solutions, and dealing effectively with affected neighbors. 

4:30 – 5:45 p.m.
Environmental Session for "Metalcasters Only"

Moderator:   Bryant Esch, Waupaca Foundry
Panelists:      Earl Miller, Hiler Industries (Kingsbury Casting Division) | IN
                      Derek MacKenzie, Kohler Company | WI
                      Paul Sheppard, Amsted Rail, Griffin Wheel | IA

Wednesday, October 10, 2018
7 – 8 a.m.
Registration/Continental Breakfast
8 – 8:45 a.m.
Safety Data Sheets (SDSs)- Understanding Common Sources of Classification Variations

Jeff Krause, HA International LLC | IL
The hazard communication Globally Harmonized System (GHS) is not always harmonized. Some of the current variations in product classification will be covered as we explore current trends in the differences we are seeing.

8:45 – 9:30 a.m.
Naturally Occuring Radioactive Materials & Waste Management

John O’Neil, Chase Environmental Group Inc.  | TN 
How to properly identify radioactive materials as NORM and the available waste management and disposal options available in the United States.

9:30 – 10:30 a.m.
EHS Hot Topics

Air Quality - Jeet Radia, McWane Inc. | AL 
Water & Waste – Holly Hurst David J. Joseph Co. | UT 
Health & Safety - Tom Slavin, Cardno ChemRisk | IL

  • What are the latest regulatory issues keeping metalcasters awake at night?
  • How is AFS helping metalcasters anticipate and prepare for new regulatory impacts?
10:30 – 10:45 a.m.
Refreshment Break
10:45 – 11:30 a.m.
Sustainability Successes

Winners of the 2018 Green Foundry Case Study Awards

11:30 a.m. – 12:15 p.m.
Silica From OHSA's Perspective

OSHA Policy Staff Invited

12:15 – 12:30 p.m.
Division 10 Award Presentations

AFS Division Individual Awards
2017 AFS Metalcasting Safe Year Awards

12:30 – 1:30 p.m.
Lunch with Exhibitors
1:30 – 2:15 p.m.
Building and Sustaining a Safety Culture

Dr. Ken Chapman, Ken Chapman & Associates | AL 

  • Why everything that counts can’t be counted
  • Hitting the ceiling – shifting from compliance to ownership
  • Where are you today? 
  • Creating ownership with a moral dimension
2:15 – 3 p.m.
Determining and Documenting "Feasibility" of Silica Exposure Control Methods

Bob Scholz, TRC Environmental | WI 

  • Describe a process for evaluating the feasibility of options to control silica exposures in foundries
  • Review criteria for judging feasibility, with examples
  • Emphasize the need to focus feasibility determinations on root causes of exposure
3 – 3:30 p.m.
Refreshment Break with Exhibitors
3:30 – 4:15 p.m.
Contractor Management

Andrew Kress, Waupaca Foundry | WI                    

  • A review of the Waupaca Foundry Contractor Management Program
  • General guidelines for contractor management (requirements before coming on site) training; proof of insurance; plant escort or site contact
  • Lessons learned, and recommendations from, real-life issues encountered with contractors
4:15 – 5 p.m.
Discussing Silica Alternatives-Foundries Successfully Making the Change

William Johnston, Engineering Manager Ellwood Engineered Castings | OH 
William will share his foundry’s process for evaluating, and experience of implementing, a switch to non-silica media for molds and cores. They now have eight months of experience working with non-silica ceramic sand.

Jack Scott, General Manager-HR/Purchasing Eagle Foundry | OR
Capitalize the initial start-up costs, don’t expense it! Hear about the exciting ways this one decision, to go with ceramic media, will 
change profitability throughout your foundry.

5:30 p.m.
Annual Reception with Exhibitors

Networking, time with Exhibitors, hors d ’oeuvres, drinks and door prizes.

Thursday, October 11, 2018
7:30 – 8 a.m.
Registration/Continental Breakfast
8 – 8:45 a.m.
Best Practices for Refractory Systems

Pete Satre, Allied Mineral Products | OH 

8:45 – 9:15 a.m.
Powered Industrial Sweeper crystalline Silica Exposure Study

Jason Lang, RHP Risk Management Inc. | IL
The OSHA Standard on Respirable Crystalline Silica reads, “The employer shall not allow dry sweeping or dry brushing where such activity could contribute to employee exposure to respirable crystalline silica unless wet sweeping, HEPA-filtered vacuuming or other methods that minimize the likelihood of exposure are not feasible.” How are powered industrial sweepers viewed under the standard? Do these sweepers increase or decrease worker exposures? How effective are wet methods and HEPA filters with regards to powered sweeping? AFS sought to conduct a study to help answer these questions.

9:15 – 10 a.m.
Silica Compliance Case Studies

Glenn Huneycutt, Charlotte Pipe & Foundry Company | NC (organizer)
Chris Wallen, Hiler Industries-Accurate Castings Division | IN
Bob Forrester, Neptune Technology | AL

10 – 10:15 a.m.
Refreshment Break
10:15 – 11 a.m.
Method Demonstration for Foundry Personnel: Silica Exposure Root Cause Identification

Rebecca Farrell, TRC Environmental | WI 

  • Brief recap of previous presentation
  • Discussion of method—instrument selection, instrument setup, and procedure
  • Results—Presentation of results and problems encountered
  • Concluding remarks on the study and potential extensions on the method
11 – 11:45 a.m.
Safety & Health Management Systems (ISO 45001) And Why It Matters

Tom Slavin, Cardno ChemRisk | IL 
The new ISO 45001 safety and health management systems standard is a game-changer for workplace safety and health. We will explore what it means, how it can help and why it matters to you. We will also discuss alternative management systems that may be a better fit for some foundries 

11:45 a.m. – 12:45 p.m.
12:45 – 1:30 p.m.
Respirable Dust Mapping-Applications of a Useful Tool in Determining Silica Exposures

Erik Pylkas, Insight IH Consulting LLC | WI 
All foundries are familiar with the compliance sampling for respirable crystalline silica. Fewer are knowledgeable of contaminant mapping of the concentrations within their facility. This talk will compare the two methods, the drawbacks and benefits of each, and discuss the proper time to deploy each method.

1:30 – 2:15 p.m.
Medical Surveillance

Paul Lynes, Finger Lynes Engineering | TN

  • Learn the Who, What, and When of requirements for medical surveillance
  • Hear what NOT to do regarding medical surveillance
  • Receive the forms necessary for medical surveillance documentation
2:15 – 3 p.m.
Respirable Crystalline Silica-Avoiding Monitoring Pitfalls and Incomplete Results

Donald Ewert, RJ Lee Group Inc. | PA
An engaging presentation on frequent sampling errors that occur and how to do it right the first time. Learn to select work task exposure groups, the need for calibrating equipment, and how to get representative samples from an ever-changing environment. You’ll also leave with tools to reduce or fully abate penalties that OSHA may propose by challenging the science behind unfavorable test results. Participants will leave with a portfolio of pitfalls to avoid and an understanding of how sample collection practices influence the analytical results they receive from the lab.

3 – 3:45 p.m.
Health and Safety Session for "Metalcasters Only"

Moderator:   Glenn Huneycutt, Charlotte Pipe & Foundry Company | NC
Panelists:      Brent Charlton, Metal Technologies Auburn LLC  | IN
                       Bob Forrester, Neptune Technology Group Inc. | AL
                       Andrew KressWaupaca Foundry | IN

3:45 p.m.


Cancellations & Substitutions

Substitutions will be accepted anytime. However, cancellations of confirmed registrants with full refund of fees will not be accepted unless received at least two weeks prior to the conference date. In the unlikely event the conference is cancelled for any reason, AFS liability is limited to the return of the registration fee.