Table 2. OSHA Estimated Costs for Engineering Controls and Ancillary Development NAICS
Engineering Industry 331511 Iron foundries
331512 Steel investment foundries 331513 331524
Steel foundries (non-investment)
331525 331528 Various
Aluminum foundries Copper foundries
Other nonferrous foundries
Captive foundries Total
controls (includes abrasive blasting)
$11,372,127 $3,175,862
$3,403,790 $5,155,172
$1,187,578 $914,028
$6,993,368 $32,201,925
be closer to $1.5 billion a year. In addi- tion, OSHA’s ancillary cost estimation of $9 million/year is much lower than the industry’s estimate of more than $90 million/year (Tables 1-2). Perhaps the largest issue is that it
is going to be difficult for metalcast- ers to meet the OSHA proposed PEL. According to OSHA’s data, a portion of the metalcasting industry already exhibits noncompliance with the current PEL (Table 3). More than 40% of facilities are noncompliant
Respirators
$645,546 $179,639
$193,194 $291,571
$67,272 $51,701 n/a
$1,428,925
Exposure assessments
$2,612,775 $739,312
$794,973
$1,220,879 $309,403
$212,778 n/a
$5,890,120
Medical
surveillance $223,005
$62,324 $67,027 $101,588
$23,668 $17,937 n/a
$495,549
with the current 100 µg/cu.m limit in three job categories: cleaning/finish- ing operators, sand system operators and abrasive blasting operators. More than 30% are noncompliant in furnace, knockout, pouring and maintenance operation. Te lack of compliance stems largely from the lack of a ready, cost-effective solution. OSHA’s cost analysis estimates include only the cost to reduce PEL from 100 µg/cu.m to less than 50 µg/cu.m and not the costs for those already above the current
Training
$216,228 $58,892
$65,679 $97,006
$23,448 $16,949 n/a
$478,202
Regulated areas
$241,133 $67,110
$72,174 $108,935
$25,095 $19,314 n/a
$533,761
Total
$15,310,814 $4,283,139
$4,596,837 $6,975,151
$1,636,464 $1,232,707 $6,993,368
$41,028,480
limit to progress to the new, more stringent limit. Te disparity in costs goes hand in hand with the disparity in feasibility assumptions. OSHA’s numbers assume a few examples of workable methods in a handful of metalcasting facilities can be applied broadly across the entire industry with the same success. AFS and the industry contend this one- size-fits-all approach will not work, as dust sources are not the same at every facility. A significant portion of costs
40 | MODERN CASTING November 2013
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