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What to Expect from the Proposed Silica Rule


The proposed silica rule cuts the current PEL in half and will have a significant impact on the U.S. metalcasting industry. TOM SLAVIN, SLAVIN OSH GROUP, LLC, CHICAGO, AND SHANNON WETZEL, SENIOR EDITOR


exposure limit (PEL) for crystalline silica were formally released by the U.S. Occupational Safety and Health Administration (OSHA) on Sept. 12. Te announcement of the proposal, which had been under review since February 2011, set the metalcasting industry into a flurry of activity to understand how the new regulations differ from the current standard, how the changes will impact compliance and whether compliance is economi- cally and technically feasible. Te proposal would significantly tighten the current PEL of 100 micrograms of respirable crystalline silica per cubic meter of air (µg/cu.m) to 50 µg/cu.m, with an action level of 25 µg/cu.m.


A OSHA said it would provide


90 days for comments on the draft regulations, although industry, includ- ing the American Foundry Society,


long time in the mak- ing, the proposed draft regulations lower- ing the permissible


has asked for an additional 90 days. According to AFS Executive Vice President Jerry Call, the rule’s require- ments will have a substantial impact on the foundry industry as currently proposed and “given the sheer size of the proposed rule, docket and support- ing documents,” the association and its members need more time to review the comprehensive proposal and pre- pare comments. OSHA plans to hold public hearings beginning March 2014 in Washington D.C.


Economic and Technological Feasibility


OSHA’s rule applies to respirable


crystalline silica, with “respirable” defined as having particles less than 5 microns in diameter. Human hair is 80 microns in diameter. Te agency estimates 2.2 million work- ers will be affected by the proposed rule, which applies to all of general industry including metalcasting. Metalcasting stands to be one of the most affected sectors.


Table 1. Estimated Costs for the Metalcasting Industry to Comply with Proposed Silica Ancillary Requirements According to Environomics Report


PEL=100 AL=50


Exposure assessment


Health screening/surveillance Regulated areas


Respiratory protection


Hazard communication/training Recordkeeping


Competent person Total


12.3 13.2 10.8 8.1 4.8 0.6 3.1


PEL=50 AL=50


11.4 8.8


13.8 20.6 3.7 0.8 3.1


PEL=50 AL=25


$18.1 million $28.7 million $13.8 million $20.6 million $8.1 million $1.4 million $3.1 million $93.8 million


Te current PEL of 100 µg/cu.m of


respirable crystalline silica was adopted in 1971. OSHA has sought to update the standard because the current one is based on research from the 1960s and uses complicated formulas. Te ultimate goal is to protect workers from silico- sis, lung disease and kidney disease. Te new standard is one of the most significant and comprehensive health rulemakings undertaken by OSHA. To comply with the new standard,


metalcasting facilities face two major challenges: economic impact and technical feasibility. A wide gap of disparity between OSHA assumptions and industry assumptions on cost and feasibility makes for a potentially con- tentious comment and hearing period for the proposed silica standard. OSHA estimates the cost for


additional controls for the metalcasting industry to comply with the lowered PEL to be $32 million a year. Te met- alcasting industry estimates the cost to


An economic study performed by Environomics Inc. figured $45,000 for a 2 cu.yd., 40-horsepow- er vacuum system with HEPA filter would be needed to achieve compliance, vs. a proposed $5,000, 15-gallon system.


November 2013 MODERN CASTING | 39


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