OSHA finds Waupaca company lacked proper precautions for using sulfur dioxide at its foundry core manufacturing, metal coating facility

Employer name: Alliance Industries Inc.
Waupaca, Wisconsin

Citations issued: June 27, 2016

Investigation findings: The U.S. Department of Labor’s Occupational Safety and Health Administration

issued nine serious violations and one other-than-serious safety violation to  Menasha-based Alliance Industries Inc. A February 2016 complaint investigation found the company failed to comply with OSHA’s process safety management standards for using sulfur dioxide at its Waupaca facility that manufactures foundry sand cores and performs metal coating.

An investigation by the agency’s Appleton area office found the company failed to:

• Incorporate good engineering practices for the sulfur dioxide delivery system.
• Compile process safety technology and equipment information for the sulfur dioxide delivery system.
• Develop and implement a mechanical integrity program for the sulfur dioxide delivery system.
• Conduct a process hazard analysis of the sulfur dioxide delivery system.
• Develop written procedures for start-ups, shutdowns and maintenance of the sulfur dioxide delivery system.
• Conduct an annual inspection of energy control procedures.

Quote: “Sulfur dioxide is a toxic gas that can cause respiratory and other serious health issues when inhaled,” said Robert Bonack, OSHA’s area director in Appleton. “When highly hazardous chemicals are not properly controlled and stored, there is a potential for unintentional release. Companies using sulfur dioxide in their manufacturing process must utilize engineering and administrative controls to reduce the potential for an uncontrolled release and take steps to protect workers from exposure.” 

Proposed Penalties:  $41,580.

View Citations here.

To ask questions, obtain compliance assistance, file a complaint, or report amputations, eye loss, workplace hospitalizations, fatalities or situations posing imminent danger to workers, the public should call OSHA’s toll-free hotline at 800-321-OSHA (6742) or the agency’s Appleton Area Office at (920) 734-4521.