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May 1, 2008

April 3, 2018. 2018 IMF Presentation. May 1, 2008. Ellwood Engineered Castings Hubbard, Ohio. OSHA Silica Standards Comparison. EEC Air Testing Results. Total of 29 air samples taken throughout the foundry. Old Standard – 100 µg/m³ PEL 9 of the 29 samples were above the PEL limit.

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May 1, 2008

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  1. April 3, 2018 2018 IMF Presentation May 1, 2008 Ellwood Engineered Castings Hubbard, Ohio

  2. OSHA Silica Standards Comparison

  3. EEC Air Testing Results • Total of 29 air samples taken throughout the foundry. • Old Standard – 100 µg/m³ PEL • 9 of the 29 samples were above the PEL limit. • That equates to 70% passed, 30% failed the standard. • New Standard – 50 µg/m³ PEL • 19 of the 29 samples were above the new PEL limit. • That equates to 34% passed, 66% failed the new standard. • New Standard – 25 µg/m³ Action Level (AL) • 28 of the 29 samples were above the new AL limit. • That equates to 3% passed, 97% failed the new AL standard .

  4. Silica Sand Replacement Project EGI Reps EEC Reps Tech Reps Mike Anthony Ben Conaway Pat Callihan Nicole Baker Adam Scarmack Matt DeWood Bobbie Campbell Tom Skladanek Claude Krause William Johnston Hank Stull

  5. Products Evaluated

  6. Evaluation Criteria

  7. Testing Results

  8. 1st Molding Trial • Three mold trial : • (2) 10477-V molds 6 tons each • (1) 10944 mold 30 tons • Objectives : • Monitor all sand properties • Evaluate mold ability of the ceramic media • Monitor the mold cooling cycles • Evaluate shakeout performance • Evaluate potential dimensional changes • Monitor mold life at customer facilities

  9. Sample Molds

  10. Ceramic Reclamation Objectives • Condition ceramic material back to reusable condition. • Capture/document reusable ceramics, dust, coarse/oversize material. • Evaluate pH, ADV, LOI on reclaimed material and compare with original ceramic properties. • Attempt to quantify amount of loss of ceramic material due to reclamation process. • Test reclaimed material for silica or other contamination vs. baseline ceramic characteristics. (CARBO and Univ. of Northern Iowa) • Test dust for silica or other contamination. (CARBO)

  11. 2nd Molding Trial • Two mold trial : • (1) 50354 stool 13 ½ tons • (1) 10854 mold 9 ½ tons • Objectives : • Monitor all sand properties on reclaimed media • Evaluate mold ability of the ceramic media • Monitor the mold cooling cycles (50354) • Evaluate potential dimensional changes (10854)

  12. Sample Castings

  13. Samples from August 2017 • Respirable silica is noticeably lower • Silica contained within “parting powder” used on the conventional cope/drag molds may need replaced as it may still be adding to our silica content

  14. Foundry Cleaning Project

  15. Foundry Cleaning Photos Before After

  16. Foundry Cleaning Photos Before After

  17. Foundry Cleaning Photos Before After

  18. Foundry Cleaning Photos Before After

  19. Foundry Cleaning Photos Before After

  20. Foundry Conversion Summary • Cleaning completed 2-16-18 • Silica sand removed – 1700 tons • Dust removed – 35 tons • Ceramic “sand” replacement – 1500 tons • Air quality resampling – April/May

  21. Silica Sand Replacement Costs • Sand/dust disposal - $ 62,000 • Vac truck cleaning - $ 178,000 • Replacement ceramic • “sand” - $1,008,000+

  22. OSHA Fines • Categories: • Other than serious - $ 12,934 • Serious - $ 12,934 • Willful - $129,336 • Repeat - $129,336 • Failure to Abate - $ 12,934/day

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