What's New

The U.S. Environmental Protection Agency (EPA) is under a court-mandated deadline to issue new area source rules for Hazardous Air Pollutant (HAP) emissions from 54 industry sectors. The Non-Ferrous Founders’ Society (NFFS) and the American Foundry Society (AFS) have learned that a rule for Aluminum, Copper, and Other Nonferrous Foundries (non- diecasting) will be included in the final group to be issued in June 30, 2009.

To meet its deadline, the agency must have a draft Proposed Rule written by no later than January, 2009. Before preparing the draft, however, the agency first needs to collect some production and HAP emissions data from the industry to support the rulemaking. Complicating this effort, however, the EPA is limited in the number of data questionnaires it can actually send out to foundries without triggering the restrictions of the Paperwork Reduction Act. In fact, the agency can only send nine questionnaires to each industry segment, to be answered on a completely voluntary basis, for a total of 27 potential industry responses.

To try to fill the information gap such a limited data collection creates, NFFS and AFS have agreed to cooperate in providing additional supplemental data on non-ferrous foundries to the EPA for its information and consideration. The two metalcasting societies will be posting the industry’s own survey forms - one for aluminum foundries, a second for copper-alloy and other non-ferrous metals (including magnesium, titanium, zinc, lead, nickel-base and beryllium-base alloys) – on their respective websites for access by all non-ferrous foundries.

Our goal in doing this is two-fold. First, we want to assure that any rule issued by the EPA is based upon a complete analysis of the HAP emissions emanating from nonferrous foundries. Second, we hope to limit as much as possible the imposition of needless or contra-competitive costs and paperwork burdens on foundries by insuring that EPA’s new rule recognizes the practices and controls already in place and the positive effect those have had in reducing HAP emissions from the industry.

The societies will submit the information we obtain to EPA in the form of a composite report. That report WILL NOT identify any facilities by name or location. Moreover, as an industry-directed project, your participation is completely voluntary, and no monitoring or emissions testing is required to respond to this request.

While your response to this general information questionnaire is completely VOLUNTARY, NFFS and AFS strongly urge your cooperation so we can achieve our objectives of offering EPA a general assessment of the industry for their rulemaking effort, and effectively representing the concerns and interests of copper and other nonferrous foundries that may be covered by EPA’s proposed area source rule.

To access the Copper & Other Nonferrous Foundry Survey forms and instructions, CLICK HERE

A report released by the Office of Advocacy of the U.S. Small Business Administration finds that currency exchange rate pressures lead to an increase in the exit rates very small manufacturers (fewer than 20 employees). According to the author of the paper, small manufacturers in high-tech industries are more insulated from international competitive pressures than those in other sectors.

The study, The Impact of International Competition on Small-Firm Exit in U.S. Manufacturing, focused on 1990 to 2004. The author noted little variation in the overall exit rate of small manufacturers over time, but a reasonable amount of variation across firm size and industry. Factors affecting exit across firm sizes included overall economic activity, labor costs, and whether the firm’s industry sector produced consumer goods. Changes in an industry’s import share produced mixed results across time periods and firm sizes.

For a complete copy of the new SBA report, click here.

WASHINGTON -- The U.S. Department of Labor's Occupational Safety and Health Administration (OSHA) has announced a new National Emphasis Program (NEP) to target worksites where employees are at risk for developing silicosis. Silicosis is a disabling, nonreversible and sometimes fatal lung disease caused by breathing in a large amount of crystalline silica. Visit www.osha.gov for more information on hazard recognition and possible solutions to silica exposure.

"Exposure to silica threatens nearly two million American employees annually," said Assistant Secretary of Labor for OSHA Edwin G. Foulke, Jr. "Under this program, OSHA will work diligently to maximize the protection of employees and eliminate workplace exposures to silica-related hazards."

The NEP compliance directive builds on policies and procedures instituted in the 1996 Special Emphasis Program and includes an updated list of industries commonly known to have overexposures to silica; detailed information on potential hazards linked to silica and about current research regarding silica exposure hazards; guidance on calculating the Permissible Exposure Limits (PELs) for dust containing respirable crystalline silica in the construction and maritime industries; and guidance on conducting silica-related inspections.

Two additional elements included in the directive are an evaluation procedure for recording reductions of employee exposures to silica, as well as information on outreach programs, partnerships and alliances with employers to share resources and training to reduce employee exposures.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's working men and women by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health.

For a full copy of the OSHA Silica NEP release, click here

NFFS receives OSHA grant to provide
Electrical Safety/NFPA 70E Arc Flash training seminars to foundries

NFFS is pleased to announce that the Society has received its fourth Susan B. Harwood grant from OSHA. The new grant will fund the development of bilingual (English and Spanish) training materials and provide for the conduct of Electrical Safety/Arc Flash training seminars for small business owners and their employees in the cast metals industry. The session is appropriate for ferrous and non-ferrous operations, including foundries, die casters, and secondary smelters. Students attending the training seminars will receive a CD-Rom of the bilingual materials and a written compliance materials. Additional information will be provided as it becomes available.

In 2006, NFFS receive and OSHA grant to provide training seminars addressing Workplace Emergency Planning topics. The seminars will be held in 2008 in conjunction with the Electrical Safety/Arc Flash training seminars.

In 2005, NFFS received an OSHA grant to develop a Lockout/Tagout Training Seminar series for foundries. This grant provided funding for the development of bilingual Lockout/Tagout training and compliance materials in addition to providing 9 regional training seminars. Although the seminars have been completed, the training materials and written compliance program are available at the NFFStar Lockout/Tagout Materials homepage.

In 2004, NFFS received an OSHA grant to develop and distribute a bi-lingual Lead Hazards Training program for foundries. As announced by NFFS in September, 2005, the project has been completed and is available for download or for delivery in printed format at the NFFStar Lead Hazards website.

The National Institute for Occupational Safety and Health (NIOSH) has issued a new publication called Ergonomic Guidelines for Manual Material Handling. According to NIOSH, manual material handling (MMH) work contributes to a large percentage of the more than half million cases of musculoskeletal disorders reported annually in the U.S. Musculoskeletal disorders often involve strains and sprains to the lower back, shoulders and upper limbs. They can result in protracted pain, disability, medical treatment and financial stress for those afflicted with them, and employers often find themselves paying the bill, either directly or through workers' compensation insurance. At the same time, employers must cope with the loss of the full capacity of their workers.

Though OSHA has yet to published an actual ergonomics standard, foundries may find the NIOSH booklet useful and relevant. It offers suggestions to improve the handling of rectangular, square and cylindrical containers, sacks, and bags. Download a copy of the 68 page document.