Released on November 22, 2011

Improper floor openings, excessive air contaminants, faulty electrical wiring and high lead levels were the top violations committed by metalcasting facilities of various types in FY2011, according to the latest data released by the U.S. Occupational Safety and Health Administration (OSHA).

OSHA regularly audits manufacturing companies, including metalcasting facilities, and tallies the number of violations incurred by each plant. The administration organizes the metalcasting industry into several categories, including gray and ductile iron facilities, steel facilities, aluminum facilities and other nonferrous facilities (excluding copper).

According to the results of the audits during the last fiscal year, gray and ductile iron casters most commonly were cited for unguarded stairway and other floor openings. Rounding out the top-three for the category were insufficient records of injury and illness data and violating general electrical requirements.

Air contaminants most often incurred citations for steel metalcasting facilities. Overhead and gantry crane violations were second on the list, and failing to utilize an OSHA log was third.

Aluminum facilities most often were tagged with electrical wiring methods violations, followed by lockout/tagout and general machine violations. Other nonferrous facilities most often were guilty of lead, general machine and respiratory protection violations.Following are the full lists of top-10 OSHA violations in 2011:

Gray Iron & Ductile Foundries

1. Stairway floor openings and floor openings not guarded.
2. Recording Criteria: Employer must keep records and record each fatality, injury and illness.
3. Electrical: General requirements.
4. Recordkeeping Criteria: Injury or illness that meets recording criteria must be recorded if it results in death, days away from work, restricted work or transfer to another job, medical treatment beyond first aid.
5. Mechanical Power: Transmission apparatus.
6. Lockout/Tagout.
7. Machines: General requirements.
8. Forms: Not utilizing OSHA log.
9. Respiratory Protection.
10. Confined Spaces: Permit required.

Steel Foundries

1. Air Contaminants.
2. Overhead and Gantry Cranes.
3. Forms: Not utilizing OSHA log.
4. Respiratory Protection.
5. Electrical: General requirements.
6. Electrical: Wiring methods.
7. Powered Industrial Trucks.
8. Mechanical Power: Transmission apparatus.
9. Recordkeeping Criteria: Injury or illness that meets recording criteria must be recorded if it results in death, days away from work, restricted work or transfer to another job, medical treatment beyond first aid.
10. Lockout/Tagout.

Aluminum Foundries

1. Electrical: Wiring methods.
2. Lockout/Tagout.
3. Machines: General requirements.
4. General Requirements: Housekeeping and floor loading.
5. Powered Industrial Trucks.
6. Hazard Communication: Must use Material Safety Data Sheets, labeling and training.
7. General Requirements: Housekeeping, safe clearances for aisles and passageways, floor loading for storage.
8. Occupational Noise Exposure.
9. General Duty Clause.
10. Respiratory Protection.

Nonferrous Foundries (except aluminum & copper)

1. Lead Standard.
2. Machines: General requirements.
3. Respiratory Protection.
4. Hazard Communication: Must use Material Safety Data Sheets, labeling and training.
5. Lockout/Tagout.
6. Abrasive Wheel Machinery: Pedestal grinders, work rests and tongue guards missing or not adjusted properly.
7. Electrical: Equipment shall be free of recognized hazards that are likely to cause death or serious harm.
8. Flammable and Combustible Liquids.
9. Eye and Face Protection.
10. Powered Industrial Trucks.