Atlas Central Corporation

Plain-English summary

Atlas Central Corporation removed paint from a Cleveland bridge by abrasive blasting inside a ventilated containment. OSHA cited employee exposure to lead, total dust, and cadmium, along with deficiencies in exposure controls, monitoring, written programs, housekeeping, and training. Judge Ken S. Welsch vacated the dust and lead exposure and engineering-control items because the Secretary did not prove that the proposed controls were feasible and would significantly reduce exposure. He also vacated the compressed-air cleaning items because the record did not show that the company's dust collection system failed to capture the resulting dust. The judge affirmed violations involving lead biological monitoring, cadmium exposure assessment and competent-person duties, the written lead program, contamination in the eating area, and lead and cadmium training. He rejected repeat classification because the earlier final order involved a different corporate employer, and assessed $2,500 in total penalties.

Decision snapshot

• Cited standard(s): 29 C.F.R. §§ 1926.55(a), 1926.55(b), 1926.62(c)(1), 1926.62(e)(1), 1926.62(e)(2)(ii), 1926.62(h)(5), 1926.62(i)(4)(ii), 1926.62(j)(2)(i)(A), 1926.62(l)(1)(iv), 1926.1127(d)(1)(i), 1926.1127(k)(6), and 1926.1127(m)(4)(iii)(A).
• Outcome: Exposure, engineering-control, and compressed-air items vacated; monitoring, assessment, program, housekeeping, and training items affirmed; $2,500 total penalty assessed.
• Key point: Proposed exposure controls were not established as feasible without proof that they would significantly reduce exposure, but the record independently supported several monitoring, program, housekeeping, and training violations.

Full text (OSHRC public release)

))))))))))))))))))))))))))))))))))))))))))))),
Secretary of Labor, *
Complainant, *
*
v. * OSHRC Docket No. 97-630
*
Atlas Central Corporation, *
Respondent. *
)))))))))))))))))))))))))))))))))))))))))))))-

APPEARANCES

                                      Mary Anne Garvey, Esq.                F. Benjamin Riek, III, Esq.
                                      Office of the Solicitor               Riek & Associates Co., L.P.A.
                                      U. S. Department of Labor             Cleveland, Ohio
                                      Cleveland, Ohio                               For Respondent
                                               For Complainant

Before: Administrative Law Judge Ken S. Welsch

                                                           DECISION AND ORDER
                 Atlas Central Corporation (ACC) is engaged in the business of industrial painting and

sheeting. On October 22, 1996, ACC was removing paint by abrasive blasting from underneath
the Denison Avenue bridge in Cleveland, Ohio, when the project was inspected by the
Occupational Safety and Health Administration (OSHA). As a result of OSHA’s inspection, ACC
received three citations on April 14, 1997, alleging employees’exposure to lead, total dust, and
cadmium. ACC timely contested the citations.
Citation No. 1 alleges serious violations of § 1925.55(a) (item 1a) for exposing employees
to concentrations of total dust above the threshold limit value; § 1926.55(b) (item 1b) for failing
to implement feasible engineering or administrative controls to reduce employees’exposure to
total dust; § 1926.62(h)(5) (item 2a) for not using compressed air for removing lead from surfaces
in conjunction with a ventilation system designed to capture airborne dust; § 1926.1127(k)(6)
(item 2b) for also not using compressed air to remove cadmium from surfaces in conjunction with
a ventilation
system designed to capture the cadmium; § 1926.62(j)(2)(i)(A) (item 3) for failing to repeat
biological monitoring on employees at least every six months; § 1926.1127(d)(1)(i) (item 4a) for
failing to determine whether employees would be exposed to airborne cadmium; and
§ 1926.1127(d)(1)(i) (item 4b) for failing to designate a competent person capable of identifying
cadmium hazards. The serious citation proposes a total penalty of $2,375.
Citation No. 2 alleges repeat violations of § 1926.62(c)(1) (item 1a) for exposing
employees to concentrations of airborne lead above the permissible exposure limit (PEL); §
1926.62(e)(1) (item 1b) for failing to implement feasible engineering or administrative controls to
reduce employees’exposure to lead; § 1926.62(e)(2)(ii) (item 1c) for failing to have a complete
written lead compliance program; § 1926.62(i)(4)(ii) (item 2) for failing to maintain eating areas
free as practicable from lead contamination; and § 1926.62(l)(1)(iv) (item 3) for failing to provide
annual lead training to each employee. The repeat citation proposes a total penalty of $8,000.
Citation No. 3 alleges an “other” than serious violation of § 1926.1127(m)(4)(iii)(A) for
not ensuring that its training program contained the health hazards associated with cadmium
exposure. The citation proposes no penalty.
The hearing was held in Cleveland, Ohio, on March 9 - 14, 1998. The parties were
represented by counsel and post-hearing briefs were filed. ACC argues that its containment to
perform abrasive blasting implemented all feasible engineering and administrative controls to
reduce employees’exposure to lead and total dust. The alleged violations involving engineering
controls are vacated for the Secretary’s failure to show that the recommended controls would
substantially reduce employee exposure.
The Inspection
ACC repaints bridges for the Ohio Department of Transportation. The bridge painting
season is April 15 through approximately October 30th of each year (Tr. 336). On October 12,
1996, ACC began its repainting work on the Denison Avenue Bridge, which spans over eight
lanes of Interstate 71 in Cleveland, Ohio (Exh. R-3; Tr. 354, 360). Ruhlin Company, general
contractor, contracted ACC to remove the existing paint and repaint the bridge (Exh. R-16; Tr.
37, 169-170). The project was completed by the end of November, 1996 (Tr. 360).

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The existing paint is removed by abrasive blasting, which is the use of highly pressurized
air to direct abrasive materials through a blasting nozzle to the painted surface. The abrasive
material is steel grit or a combination of steel grit and steel shot. During abrasive blasting, the air
pressure through the nozzle is 100 to 120 pounds per square inch (psi) and the abrasive material is
propelled at a velocity in excess of 400 miles per hour. The abrasive blasting removes the paint
and creates a profile of one to three mills1 on the surface, which allows new paint to adhere (Tr.
42-43, 466-467). As the paint is removed, small particles of paint and other debris become
airborne in clouds of dust. The employees are expected to clean 1,000 to 1,500 square feet per
day (Tr. 352-353).
Prior to the abrasive blasting, a containment is constructed around the portion of the
bridge to be cleaned. The containment is to protect the environment (Tr. 332-333). At the time
of OSHA’s inspection, ACC’s employees were removing paint from underneath the south
abutment area of the bridge. The containment constructed by ACC was tent-like, consisting of
tarpaulins (tarps) hung from the bridge (Exhs. C-1, C-2, C-3; Tr. 43, 177, 299-300, 473). The
containment enclosed the area from the southbound lanes of Interstate 71 to the top of the sloped
concrete abutment. As shown by ACC, the containment was designed to be 27 feet from
interstate to abutment, 70 feet long and 10 feet high for 17,500 cubic feet (Exhs. C-24, R-12).
However, OSHA measured the area after the containment was removed as 89 feet wide, 78 feet
from the columns to the concrete abutment and 16 feet high for 71,600 cubic feet (Exh. R-18, C-
33, pp. 2, 4; Tr. 321). The engineering plans, on the other hand, show the width of the bridge is
62 feet, the distance from the column to the abutment is 75 feet, and the height from the ground
to the bottom of the 5-foot steel girders is 14 feet, 9 inches (Exh. R-3). While abrasive blasting,
the employees worked from scaffolding hung from the girders. They were tied-off and wore air-
supplied respirators (Exhs. C-3, R-40, p. 25; Tr. 1079).
Because of the concentrations of dust generated by the abrasive blasting inside the
containment, ACC used a dust collector to exhaust and filter the dusty air (Tr. 485-486). Three
ducts to the dust collector were located along one wall of the containment (Exh. C-2). While the
dust collector removed the dusty air from inside the containment, fresh air was drawn into the
containment from the holes and gaps in the tarps (Exh. C-35; Tr. 486). Also, along the wall
opposite

    1
     One mill equals one thousandth of an inch (Tr. 467).

                                                   3

the dust collector, two louvers (2 feet by 2 feet) were placed in the tarp at a height of 5 feet to
also allow in fresh air (Tr. 1214, 1223). The containment was kept under negative pressure.
On October 22, 1996, OSHA compliance safety and health officer Sharon Danann
inspected the Denison Avenue bridge project (Tr. 25, 35). Working at the project were Costas
Kozani, ACC’s job superintendent, three abrasive blasters, three painters and a groundsman (Tr.
300-301). As part of her inspection, Danann performed air monitoring inside the containment
while three employees (John Manis, Nick Kofinas, and Nasos Tataridis) were abrasive blasting.2
The air samples were collected by attaching pumps to the employees’belts which drew air into
sample cassettes affixed to the shoulders of the employees, outside the employees’blasting
helmets and air-supplied respirators. Danann also collected wipe samples from the surface of a
table and the spigot of a water jug inside the employees’lunch trailer (Exh. C-8; Tr. 41-42, 44,
80).
The air samples and wipe samples were submitted to OSHA’s Salt Lake City Technical
Center for analysis (Tr. 52-53). The analysis found that the three employees doing the abrasive
blasting were exposed above the PEL of 50 micrograms per cubic meter (ug/m3) for lead (Exhs.
C-4, C-6, C-7; Tr. 68, 74, 78). Based on their exposure to iron oxide, two of the employees
(Manis, Kofinas) were also exposed to total dust above the PEL of 15 milligrams per cubic meter
(mg/m3) (Tr. 71, 79). Also, two of the employees (Manis, Tataridis) were exposed to cadmium
above the action level of 2.5 ug/m3 (Exhs. C-4, C-6; Tr. 76).

                                          Discussion
                                      Alleged Violations
                                Lead and Total Dust Exposure

Citation No. 1, Item 1a and Citation No. 2, Item 1a - Alleged Violations of §§ 1926.55(a) and
1926.62(c)(1)

   Citation No. 1 alleges that two employees performing abrasive blasting were exposed to

total dust at an 8-hour, time-weighted average (TWA) of 345 and 76 milligrams per cubic meter.
Section 1926.55(a) provides that:
Exposure of employees to inhalation, ingestion, skin absorption, or
contact with any material or substance at a concentration above

   2
    The fourth employee sampled was the groundsman who was working on the bridge deck (Tr. 41).

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those specified in the “Threshold Limit Values of Airborne Contaminants for
1970” of the American Conference of Governmental Industrial Hygienists, shall
be avoided.

    The threshold limit values of airborne contaminants are contained in Appendix A to

§ 1926.55. When the Secretary incorporated the threshold limit values into the occupational
health standards, she transformed the values into PEL. Bunge Corp., 12 BNA OSHC 1785,
1788, n. 10 (Nos. 77-1622, 78-838 and 78-2213, 1986). The PEL for “inert or nuisance dust,”
which includes “all mineral, inorganic and organic dusts,” is 15 mg/m3. The air monitoring of
John Manis and Nick Kofinas was conducted on October 29, 1996, while the employees were
abrasive blasting. Manis’sample result found 345 mg/m3 of iron oxide and Kofinas’result was
76 mg/m3 of iron oxide (Exhs. C-4, C-7; Tr. 68, 79).
Although iron oxide is not a specifically regulated particulate, it was the major constituent
(largest single ingredient) of mineral dust generated during abrasive blasting (Tr. 53, 71). The
amount of iron oxide in the samples was used as the basis of showing employees’exposure to
total dust (Tr. 54).
Citation No. 2 alleges that three employees performing abrasive blasting were also
exposed to airborne lead concentrations at TWA levels of 2,789 ug/m3 (Manis), 783 ug/m3
(Tataridis), and 1,963 ug/m3 (Kofinas). These levels are 56, 16 and 39 times the PEL of 50
ug/m3 for lead. Section 1926.62(c)(1) provides that:
The employer shall assure that no employee is exposed to lead at
concentrations greater that fifty micrograms per cubic meter of air
(50 ug/m3) averaged over an 8-hour period.

    ACC does not dispute the accuracy of OSHA’s air monitoring results (Exh. C-11; ACC

Brief, p. 2). ACC argues that since it implemented all engineering controls which could not
reduce the lead and dust exposures to within the PEL, employees wore appropriate personal
protective equipment, such as blasting helmets and air supplied respirators (Exh. C-3; Tr. 43-44).
Sections 1926.55(b) and 1926.62(e) require an employer to implement feasible
engineering or administrative controls to reduce employees’exposure to total dust and lead. If
such controls fail to achieve full compliance, only then can the employer use other protective
measures to keep the employee’s exposure within permissible limits.
The Secretary does not dispute that the employees were provided appropriate personal
protective equipment and that such equipment was necessary to reduce the employees’exposure.

                                              5

However, the Secretary does not accept that ACC implemented all feasible engineering controls
to reduce the exposure to total dust and lead. Unless the Secretary establishes that there were
feasible engineering or administrative controls not implemented by ACC, violations of §§
1926.55(a) and 1926.62(c)(1) are not found.

                           Engineering and Administrative Controls

Citation No. 1, Item 1b and Citation No. 2, Item 1b - Alleged Violations of §§ 1926.55(b) and
1926.62(e)(1)

   Citation No. 1 alleges that ACC did not implement engineering or administrative controls,

including the placement of inlets to the exhaust ventilation, the use of make-up air and the
creation of mini-enclosures to reduce employees’exposure to total dust. Section 1926.55(b)
provides in part that:
To achieve compliance with paragraph (a) of this section,
administrative or engineering controls must first be implemented
whenever feasible. When such controls are not feasible to achieve
full compliance, protective equipment or other protective measures
shall be used to keep the exposure of employees to air contaminants
within the limits prescribed in this section.

   Citation No. 2 alleges that ACC did not implement engineering or administrative controls,

including the placement of inlets to the exhaust ventilation, the use of make-up air, the creation of
mini-enclosures and the rotation of employees to reduce employees’exposure to lead. Section
1926.62(e)(1) provides that:
The employer shall implement engineering and work practice
controls, including administrative controls, to reduce and maintain
employee exposure to lead to or below the permissible exposure
limit to the extent that such controls are feasible. Wherever all
feasible engineering and work practices controls that can be
instituted are not sufficient to reduce employee exposure to or
below the permissible exposure limit prescribed in paragraph (c) of
this section, the employer shall nonetheless use them to reduce
employee exposure to the lowest feasible level and shall supplement
them by the use of respiratory protection that complies with the
requirements of paragraph (f) of this section.

   Both the total dust and lead standards reference two types of controls which may be

utilized to reduce employee exposure. Administrative or work practice controls typically include
changes in the employee’s method of work and rotating the employee’s job duties. Engineering

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controls involve various mechanical devices and equipment, such as exhaust systems, fans, inlets
and enclosures (Tr. 485). An employer is expected to implement the administrative or
engineering control where feasible even though such control does not necessarily reduce the
employee’s exposure below the PEL. “The test of whether administrative and/or engineering
controls are technologically feasible is whether the controls are achievable and capable of
producing a significant reduction in exposure to air contaminants.” G & C Foundry Company, 17
BNA OSHC 2137 (No. 95-869, 1997), citing Harmony Blue Granite Co., 11 BNA OSHC 1277
(No. 14189, 1983). A control can be feasible even if it does not achieve full compliance. Id.

                Estoppel From Asserting Additional Engineering Controls
   ACC initially argues that OSHA is estopped from requiring other enclosure

configurations, given OSHA’s admission in early 1997 that general dilution ventilation was the
appropriate engineering control for abrasive blasting operations (ACC Brief, p. 20).
The facts are not in dispute. On May 8, 1996, ACC was inspected by OSHA while
performing abrasive blasting on a bridge in Van Wert, Ohio (Tr. 433-434). As a result of the
inspection, ACC received a serious citation for failing to implement feasible engineering controls
when employees’exposure to lead exceeded the PEL (Exh. R-20; Tr. 444). After filing its notice
of contest, an OSHA assistant area director stated in response to interrogatories that general
dilution ventilation with local exhausts constituted feasible engineering controls (Exh. R-21, p. 7;
Tr. 446-448).
ACC asserts that during settlement OSHA agreed to delete the engineering control
violation because ACC agreed to re-position the exhaust ventilation (Tr. 449). However, based
on the statement by OSHA that general dilution ventilation was an adequate engineering control,
ACC argues that OSHA is now prevented from pursuing other engineering controls. ACC cites
Secretary v Miami Industries, Inc., 983 F.2d 1067 (6th Cir., 1992) (employer did not have fair
notice that additional guards were needed for a machine because during a prior inspection the
inspector indicated that the guards in place were adequate) and Hamilton Die Cast, Inc.,11 BNA
OSHC 2169 (No. 79-1686, 1984) (Commission dismissed citation where an employer relied upon
previous OSHA inspection findings that a guard was not necessary on the equipment).
ACC’s estoppel argument is rejected. Equitable estoppel is an affirmative defense. The
Secretary is not estopped from enforcing a standard except where she has engaged in affirmative
misconduct, active misrepresentation and a resulting injustice to the employer. Erie Coke Corp.,

                                              7

15 BNA OSHC 1561, 1568-1570 (No. 88-611, 1992). As noted in the Erie case, previous
settlements may reflect the results of the bargaining process as to those particular citations and
can not be construed as “misrepresentations.” Also, the statement by the assistant area director in
responding to interrogatories was not shown to restrict engineering controls to dilution ventilation
or that general dilution ventilation was recommended for other than the Van Wert bridge project.
The standards cited anticipate a continuing obligation by the employer through the use of
engineering or administrative controls to reduce employees’exposure until it is at or below the
PEL.

                                 Application of § 1926.57
   ACC argues that § 1926.57(f)(3) establishes the specific requirements for the design of a

ventilation system in an enclosure used for abrasive blasting. Section 1926.57(f)(3) provides:
Blast cleaning enclosures shall be exhaust ventilated in such a way
that a continuous inward flow of air will be maintained at all
openings in the enclosure during the blasting operations.

The provisions of § 1926.57(f)(3) asserts ACC takes precedence over the engineering controls
proposed by the Secretary (ACC Brief, p. 12). ACC argues that by operation of § 1910.5(c)(1)
the particular standard at § 1926.57(f)(3) is applicable to its bridge containment and prevails over
the general engineering control standards at § 1926.55(b), which might otherwise be applicable to
the same condition, practice, or method. Lowe Construction Co., 13 BNA OSHC 2182, 2183-
2184 (No. 85-1388, 1989). The Secretary argues that § 1926.57(f) does not apply to temporary
enclosures such as ACC’s containment at the Denison Avenue bridge.
Section 1926.57 establishes standards for ventilation “whenever hazardous substances
such as dusts . . . are produced in the course of construction work” which exceed the limits
specified in § 1926.55(a). Section 1926.57(a) further provides that “[W]hen ventilation is used as
an engineering control method, the system shall be installed and operated according to the
requirement of this section.” Section 1926.57(f) involves abrasive blasting and its scope at §
1926.57(f)(8) applies “to all operations where an abrasive is forcibly applied to a surface by
pneumatic or hydraulic pressure.” By the Secretary’s terms, standards at § 1926.57(f) are not
restricted to permanent containments or enclosures.
However, § 1926.57(f) does not preempt all engineering controls contemplated by
§ 1926.55(b). The standard applies to the nature and operation of exhaust ventilation when

                                              8

ventilation is used as an engineering control to reduce dust exposures identified in § 1926.55(a).
It requires that the enclosure be ventilated to maintain an inward flow of air and an exhaust rate
sufficient to provide prompt clearance of dust within the enclosure. Section 1926.57(f)(4)
requires that the construction, installation, inspection and maintenance of exhaust systems
conform to requirements set forth in American National Standards Institute (ANSI) Z9.2-1960
and Z33.1-1961. Therefore, to the extent ventilation is contemplated by the Secretary’s
recommended engineering controls, the principals in § 1926.57(f) do apply.

                                   Controls Used by ACC
   For the Denison Avenue bridge project, ACC used canvas tarps hung from the top of the

bridge to the ground to form a tent-like containment area between the bridge concrete abutment
and the south-bound lanes of Interstate 71. The containment area was designed by Costas
Kozanis, ACC’s job superintendent and competent person. Although not specifically measured,
based on OSHA’s measurements and the engineering plans, the containment was approximately
70 feet wide along the interstate, 78 feet from the interstate to the abutment, and approximately
19 feet high from the ground to underneath the bridge (Exhs. C-18, C-24, R-3, R-12). At the end
of the sloped concrete abutment, the height was approximately 6 feet.
A dust collector with a rated capacity of 40,000 cubic feet per minute (cfm) was located
outside one side of the containment. Three ducts for the dust collector were placed in an opening
to the containment (Exhs. C-2, R-15). Fresh air was allowed into the containment through holes
and gaps in the tarps as well as two lourvers installed on the side opposite the dust collector. The
movement of air was measured with an anemometer once a week in the middle of the containment
in the range of 100 to 110 feet per minute (Exh. R-12; Tr. 351-352, 1171). The containment was
designed to provide general dilution ventilation to remove dust accumulation from inside the
containment (Exh. C-15).
ACC argues that in its larger containment with general dilution ventilation, there are lower
concentrations to iron oxide and lead because of the possible vertical downward air movement
generated by the blasting nozzles which pushes the air into the larger area below the girders.
There is no blanket of air forced past the bottom of the girders which keeps the particles between
the girders (Tr. 929-930). Under general dilution ventilation as explained by Dan Adley, the
larger particles created during the blasting process fall to the ground once they lose their kinetic
energy. This reduces the concentration of dust near the blasting operations (Tr. 989-992).

                                              9

While in the containment, employees wore appropriate personal protective equipment
during blasting operations. The equipment included a blasting helmet with a shoulder cape and a
Bullard respirator with a positive air flow. Employees also wore heavy cotton coveralls and
gloves (Exh. C-3;Tr. 43-44, 196). Outside the containment, employees changed their
contaminated coveralls in a down draft booth (Exh. R-7, Tr. 193). Also, a trailer was provided
for employees to use for meals and breaks (Tr. 144, 350).

                         Secretary’s Criticism of ACC’s Containment
   Although ACC’s general dilution ventilation reduces employee exposure to dust

contaminants at least to some extent, the Secretary argues that ACC’s containment provided no
means of systematically introducing clean air into the containment and maximizing the airflow
where the employees were abrasive blasting. The Secretary argues that additional controls were
feasible. Compliance officer Danann describes general dilution ventilation as the mixing of
contaminants with air and a general lessening of quantities relative to a containment without an
exhaust (Tr. 101, 478-479). The American Conference of Governmental Industrial Hygienists
(ACGIH) considers dilution ventilation inappropriate for work environments where contaminants
are of a toxic nature, such as lead and cadmium (Tr. 104). Section 2.3 “Dilution Ventilation for
Health”, the ACGIH states:
The use of dilution ventilation for health has four limiting factors:
(1) The quantity of contaminant generated must not be too great or
the airflow rate necessary for dilution ventilation will be impractical;
(2) Workers must be far enough away from the contaminant source
or evolution of contaminant must be in sufficiently low
concentrations so that workers will not have an exposure in excess
of the established TLV;
(3) The toxicity of the contaminants must be low; and
(4) The evolution of the contaminants must be reasonably uniform.
(Tr. 112-113).

   Dan Adley, ACC’s expert, considers the ACGIH publication as the “bible” within the

industrial hygiene community. Adley concedes that dilution ventilation is not the preferred
method of ventilation. The preferred method is to capture the containment at the source and
remove it so the employee has no opportunity of exposure. Dilution ventilation is most often
used to control vapors (Tr. 1111-1112).

                                               10

John Cignatta,3 Secretary’s expert and licensed professional engineer, describes the
containment used by ACC as a “circus tent” enclosure with general dilution ventilation (Tr. 521-
522). According to Cignatta, clean air was only introduced in a haphazard manner through holes
and gaps in the tarps. Therefore, dust from abrasive blasting continued to accumulate and be
dispersed throughout the large containment area (Tr. 551-552). Cignatta opined that
contaminated air accumulated in stagnation points and was recirculated throughout the
containment (Tr. 517). He generated illustrations based on a computer model depicting the
interior of the containment during abrasive blasting to show the airflow under general dilution
ventilation (Exh. C-33, pp. 7, 9). The computer model shows the air flow moving in no
discernable pattern. Since the employees performing abrasive blasting are at the point of
generation, the three employees appear to be inside a dense cloud of dust accumulation. The
computer model is consistent with the compliance officer’s observations inside the containment.
According to Danann, “[I]t was hard to discern the employees due to the dust clouds in their
immediate vicinity” (Tr. 90).
ACC asserts that Cignatta’s computer model is unreliable and does not depict the
containment at the Denison Street bridge project. First, ACC notes that the sloped concrete
abutment is not accurately shown. Instead of a slope, the abutment is shown as three large steps
(Tr. 686, 844-845). Cignatta agrees that 50 smaller steps probably would be a closer
approximation of the slope’s angle. Cignatta concedes that the use of three steps does have some
impact on the air flow depicted in the computer model. He was, however, unable to estimate the
extent of the impact (Tr. 686-687).
Secondly, ACC argues that the orientation of the blast nozzle shown in the computer
model as compared to actual useage is biased towards employee exposure (Tr. 846, 850-851).
The nozzle is shown pointing in a parallel direction with the girders. In reality, the nozzle for the
most part is pointed in an upward direction to clean the underside of the bridge and upper

     3
       ACC argues that Cignatta is not qualified as an expert under principals outlined in Daubert v. Merrell

Dow Pharmaceuticals, Inc.,113 S. Ct. 2786, 2794 (1993). Mr. Cignatta is accepted as an expert witness. Cignatta
is a licensed engineer and has testified as a qualified expert in at least two prior cases involving abrasive blasting
on bridges. See Manganas Painting Co., Inc., 1995-1997 CCH OSHD ¶ 31,183 (No. 94-588, September 17, 1996;
directed for review) and E. Smalis Painting Co., Inc., 1995-1997 CCH OSHD ¶ 31,113 (No. 94-1979, March 26,
1996; directed for review). He is a registered professional engineer and has authored several publications (Exh. C-
32). He has prepared reports involving computer modeling and ventilation sytems for abrasive blasting on bridges
(Exhs. C-30, C-31).

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portions of the girders (Tr. 692-693). Also, the model assumed that the nozzle is 3 cm x 3 cm
(Tr. 681). The nozzle used by ACC is a half-inch smaller in diameter (Tr. 682).
Finally, ACC argues that the holes and gaps in the tarps are incorrectly depicted in the
computer model. The number and location of the gaps and holes which provide the source of
fresh air are based on photographs taken by compliance officer Danann (Exhs. C-1, C-2; Tr. 851-
852). The computer model shows two exhaust ports (dust collectors) and five holes and gaps
along one side of the containment. However, Danann’s photographs only show a portion of the
containment, and she did not identify or measure all holes and gaps in the tarps. Similiarly, the
exhaust ducts are not shown on the sloped portion of the abutment (Tr. 858). According to ACC,
changes in the position of the exhaust ducts and holes for fresh air affects the ventilation in the
containment (Tr. 856-857). For example, the record indicates that two 2 x 2-foot wooden
louvers, not shown in the computer model, were installed across from the dust collector. The
louvers permitted some cross-ventilation of fresh air.
ACC’s arguments regarding the computer model’s depiction of its containment at the
Denison Avenue bridge have merit. However, since the abrasive blasting was done above the
cross- ventilation, there was little impact at the point of dust generation (Tr. 689). Cignatta’s
model showing the dust generation is supported by the air sampling results taken by compliance
officer Danann and her observations. It is undisputed that the employees were exposed to
excessive concentrations of airborne dust accummulations containing lead and iron oxide. Manis’
exposure was 56 times the PEL for lead and 23 times the PEL for total dust, and Kofinas’
exposure was 39 times the PEL for lead and 5 times the PEL for total dust. The computer model
is used as representative of airflow patterns within a containment with similarities to the Denison
Avenue bridge containment under general dilution ventilation. It is not considered as an accurate
depiction but is used to show how modifications in containment design may affect the
concentrations of airborne contaminants on employees performing abrasive blasting.

           Secretary’s Recommended Engineering and Administrative Controls
   The Secretary’s recommended engineering controls include (1) placement of the dust

collection unit closer to the abrasive blasting, (2) use of make-up air to reduce the high levels of

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dust around the blasters, and (3) the creation of mini-enclosures.4 The Secretary also
recommends reducing the amount of time an employee spends abrasive blasting (Tr. 104-107).
The recommended controls identified by the Secretary are claimed to reduce both the lead
and total dust exposures. According to Cignatta’s research, as the PEL for lead is approached
through the use of engineering controls, employee exposure to other contaminants, such as total
dust, is also reduced (Exh. C-29, p. 5). The Secretary’s recommended engineering controls
involve the attempted movement of airborne contaminants away from the employee’s breathing
zone. If the controls are shown feasible, equivalent reductions in employee’s exposure levels to
total dust and lead are therefore reasonably expected.
A discussion of each of the Secretary’s recommended controls follows:

1. Local Exhaust Ventilation
   The placement of dust collection by local exhaust involves the capture of airborne
   contaminants nearer the source of dust generation; abrasive blasting. The contaminants are
   captured by suspending exhaust inlets with flexible hoses in close proximity to the employees
   performing abrasive blasting. The Secretary recommends that the local exhaust be applied to the
   blasting nozzle to vacuum the generated dust (Tr. 105). The local exhaust draws the
   contaminated air away from the employees and into the dust collector (Tr. 104-105, 549). In
   ACC’s general dilution ventilation, the employees were abrasive blasting far from where the dust
   collector was exhausting the dusty air from the containment (Tr. 512).
   The feasiblity of local exhaust ventilation for abrasive blasting is not established by the
   record. It is not shown that such local exhaust equipment exists for abrasive blasting, has been
   used at other abrasive blasting jobs, or can be adapted to ACC’s abrasive blasting process.
   Abrasive blasting is not a process which permits a stationary local exhaust system. Employees
   need to freely move along the steel girders. They are expected to clean in excess of 1,000 square
   feet of steel per day (Tr. 352-353). Also, the blasting nozzle delivers the abrasive material at a
   velocity of 400 miles per hour which reduces the effectiveness of an exhaust attached to the
   blasting nozzle (Tr. 466). Even if a local exhaust system is available, the Secretary fails to identify
   any anticipated reduction in employees’exposure to contaminated dust.

   4
    The Secretary’s recommendation for the use of less dusty techniques, dust suppressant additives or media
   

   was withdrawn (Tr. 296-297).

                                                  13
   

   2. Use of Make-up Air
   The Secretary recommends the use of make-up air to reduce the levels of dust around
   employees performing abrasive blasting and to move the dust towards the dust collector (Tr. 105-
   106). Contaminated air is more efficiently moved out of the containment if fresh air is
   systematically introduced into the containment. The introduction of fresh air, when coupled with
   the use of an exhaust system, creates a “push/pull” pattern of air movement across the
   containment. Fresh air introduced at one end of the containment pushes through the containment
   while contaminated air is pulled out at the other end by the dust collector. John Cignatta, the
   Secretary’s expert, opined that if proper push/pull ventilationl5 is implemented, the dust generated
   by abrasive blasting is quickly “washed” through the containment, reducing the amount of time
   that contaminated air remains in the employees’breathing zone (Exh. C-33, p. 11; Tr. 548-549).
   Cignatta stated that the installation of louvers along one side of the containment allows for the
   systematic introduction of make-up air (Tr. 549). Cross-ventilation airflow avoids large air
   stagnation points.
   The record shows that two louvers to permit the entry of fresh air were installed across
   from the dust collector in ACC’s containment, thus creating to some extent the cross ventilation
   recommended by the Secretary (Tr. 1214, 1223). Using an anemometer once a week, ACC
   measured the airflow in the middle of the containment in excess of 100 feet per minute (Exh. R-
   12; Tr. 351-352). The Secretary fails to show that ACC did not use make-up air as part of its
   general dilution ventilation system.

2. Reducing Employee Time of Exposure
   The Secretary also recommends altering the employees’work schedules and job duties as
   an administrative control to reduce employees’exposure. By reducing an employee’s time
   abrasive blasting, the amount of time an employee spends in the containment is reduced (Tr. 256-
   257). For example, the Secretary suggests that employees can be rotated between abrasive
   blasting and painting. She argues that if administrative controls are used in combination with
   engineering controls, employees’exposure may be substantially reduced.
   The record in not clear whether ACC, to some extent, already rotates employees.
   Compliance officer Danann agrees that ACC possibly already interchanged between the blasting

   5
   Cignatta referred to push/pull ventilation also cross-flow ventilation.

                                                   14
   

   crew and paint crew (Tr. 256). She knew that some employees who had earlier been designated
   as painters were also performing abrasive blasting. Based upon the concentration levels she
   detected, Danann was unable to identify the amount of time that an employee could perform
   abrasive blasting before rotation (Tr. 256-257). As a result of working from pic scaffolding,
   employees regularly had to stop blasting, relocate the scaffolding and clean the area (Tr. 1079).
   The record does not establish the feasibility of regularly rotating employees to achieve significant
   reductions in exposure levels. ACC employs less than 15 employees .

3. Dance Floor or Mini-Enclosure
   The primary control recommended by the Secretary is the use of a dance floor, or mini-
   enclosure, which reduces the size of the containment (Tr. 105-106). In principal, the dance floor
   elevates the floor level of the containment from the ground to approximately two feet below the
   steel girders needed to be cleaned. With the mini-enclosure, the walls of the dance floor are also
   moved in to form an even smaller containment. For example, Cignatta calculates that the working
   space for a dance floor enclosure is reduced to approximately 13,300 cubic feet, as opposed to
   approximately 72,000 cubic feet in ACC’s circus-tent containment (Tr. 547). For a mini-
   enclosure 12 feet wide, he expects that the working space is further reduced to approximately
   2,000 cubic feet. Thus, there is a reduction in excess of 90% in overall volume needed to be
   ventilated (Exh. C-33; Tr. 563-565). Cignatta states that a dance floor or mini-enclosure can be
   hung from rails or suspended below the bridge. Also, the enclosure can be mounted on a semi-
   tractor trailer and lifted into position underneath the bridge by hydraulic jacks (Exh. C-33, pp. 23-
   24; Tr. 546, 578).
   By also establishing cross-flow (push/pull) ventilation in conjunction with the dance floor
   or mini-enclosure, Cignatta opines that a more directed airflow can be created from the source of
   incoming fresh air to the dust collector. The ventilation system for the dance floor or mini-
   enclosure approaches “plug flow,” which is a condition where contaminated air is washed away
   almost as fast as it is generated (Tr. 563-564).
   Also, Cignatta recommends installing a grated floor or V-trough in the mini-enclosure to
   allow spent abrasives and large paint chips to collect for easier retrieval (Tr. 561, 565-567). The
   grating or V-trough removes the abrasives and paint chips from the work area and prevents them
   from being re-disturbed into the employee’s breathing zone. Also, a retrieval system eliminates
   the need for employees to vacuum the floor to recover the spent abrasives.

                                              15
   

   With a mini-enclosure and a directed airflow system, John Cignatta testified that an overall
   reduction in employee exposure to total dust and lead is expected to be from 1% to 5% of the
   exposure levels recorded by OSHA’s air sampling (Tr. 617, 619-620). Using 5% as an example,
   Kofinas recorded total dust level of 76 mg/m3 would be reduced to 3.8 mg/m3--not above the
   PEL. Although Manis’total dust exposure of 345 mg/m3 is above the PEL at 17.25 mg/m3, his
   exposure level is substantially reduced. Similiarly, although the three employees remain
   overexposed to lead, Cignatta would anticipate substantial reductions from the use of a mini-
   enclosure and directed airflow. Manis’s exposure to lead of 2789 ug/m3 would be reduced to
   139.45 ug/m3; Tataridis’exposure of 783 ug/m3 would be reduced to 39.15 ug/m3; and Kofinas’
   exposure of 1963 ug/m3 would be reduced to 98.15 ug/m3.

                       Record Fails to Establish Feasible Controls
   

   In addition to the other controls previously discussed, the dance floor or mini-enclosure
   are also not shown by a proponderance of the evidence as feasible controls at the Denison Avenue
   bridge which would significantly reduce employee exposure to total dust and lead. The record
   shows that because of the smaller enclosed area and the obstruction caused by the steel girders to
   the airflow pattern, there may not be sufficient fresh air circulated into the area between the
   girders to reduce the contaminated dust generated by the abrasive blasting.
   In the preamble to the interim lead standard (58 FR 26590, May 4, 1993), the Secretary
   anticipated that with mechanical ventilation and an enclosure or containment as engineering
   controls, employees performing abrasive blasting would be exposed to lead levels in the range of
   18,650 ug/m3 (Exh. R-35). The monitoring results at the Denison Avenue bridge were in this
   range. Thus, ACC’s general dilution ventilation appears to meet the Secretary’s anticipated levels
   of lead exposure utilizing engineering controls.
   The airflow through a dance floor or mini-enclosure was not shown to necessarily remove
   the dust concentrations between the girders. There were approximately six girders to disrupt any
   cross airflow ventilation in the dance floor or mini-enclosure. With the dance floor or mini-
   enclosure, Cignatta testified that there was only an approximate two feet below the girders with
   an unobstructed path between the fresh air intake (louvers) to the exhaust (dust collector). The
   airflow was to move under the girders from the louvers to the dust collector (Tr. 863-864).
   However, the concentration of dust was generated between the girders at the employee’s
   breathing zone. There was no designed air flow directed to this area. The only source of air

                                              16
   

   between the girders was from the blasting nozzle which directs the abrasives to the steel. Based
   on the movement of the blast nozzle, it was not shown that air from the nozzle provided a
   downward draft which captured the dust in the air flow at the employee’s feet. The air flow
   pattern described by Cignatta may preclude the effective removal of the dust created during the
   blasting operations.
   Dr. Stanley Penkala, ACC’s expert in air science and a PhD, opined that in the mini-
   enclosure configuration, lead dust accumulates between the beams (Exh. R-28). He testified that
   Cignatta’s model does not show the rebound effects of air flow when hitting solid objects such as
   the steel girders. Penkala stated that the air flow drawn past the employee’s feet at an efficient
   rate could result in higher concentrations of dust between the girders at the employee’s breathing
   zone (Tr. 877-878). Penkala testified that Cignatta’s air flow recommendations for the mini-
   enclosure do not adequately remove dust concentrations from the area between the girders where
   the abrasive blasting operations occur (Tr. 863-864). The air flow moves in a blanket at a steady
   rate underneath the beams. It fails to capture the dust cloud between the girders (Exh. R-30; Tr.
   865). Penkala opines that the dust generated by the blasting process is not captured by the air
   flow under the girders but instead is recirculated in the area between the beams. According to
   Penkala, the dust is not removed because there is no make-up air introduced into the area (Tr.
   866-867).
   Daniel Adley, ACC’s expert and certified industrial hygienist and safety professional,
   testified that when the abrasive material from the blasting nozzle hits the girder, the pulverized
   grit and paint chips deflect in all directions depending on the orientation of the nozzle to the
   girder. Adley opined that the level of employee exposure in ACC’s containment was well within
   the range of expected lead exposure during abrasive blasting (Tr. 984). Adley had gathered the
   exposure data in abrasive blasting for the Secretary’s interim lead in construction standards (Tr.
   976-977). Also, Adley stated that Cignatta’s computer model was ineffective in predicting lead
   exposure levels because the concentrations of lead in the paint and its thickness were not
   determined (Tr. 1085-1086).
   To support their expert opinion, ACC produced two air monitoring studies. In air
   monitoring performed in 1994 during abrasive blasting of the lead levels in a containment of
   200,000 cubic feet and one of 3,000 cubic feet, the authors concluded that neither containment
   was of value in reducing an employee’s lead exposure. In fact, the smaller containment showed

                                             17
   

   lead levels three times higher on a geometric mean than the larger containment. Although the
   monitoring was conducted on a small sample, the report tends to support ACC (Exh. R-26).
   In another study performed by the Federal Highway Administration in 1995, the authors
   also concluded that higher levels of lead exposure were found in the smaller containment. The
   authors also stated that ventilation systems do not appear to be effective on reducing employee
   exposure (Exh. R-37).
   On the other hand, Cignatta did not perform any air monitoring at the Denison Avenue
   bridge. He did not observe ACC’s abrasive blasting operation or the containment at the Denison
   Avenue bridge. His computer model is flawed in its depiction of ACC’s containment. Also,
   Cignatta failed to provide quantitative data to establish the nature of any reductions that were
   anticipated in any bridge painting project where mini-enclosure or dance floor designs were used
   when compared with the general dilution ventilation used by ACC. He was unable to identify any
   contractors who used a mini-enclosure or dance floor similar to his designs for ACC (Tr. 747).
   Cignatta’s report “Computer Aided Engineering For Design of Ventilation System at
   Industrial Painting Projects” is of limited value to this case (Exh. C-30). The primary example
   discussed involved the abrasive blasting of a water tank where a vertical containment was
   designed. The containment had the fresh air intake at the top and the dust collector at the bottom,
   creating a downward air flow pattern past the employees working from pickboards. The greatest
   reduction in exposure resulted, however, from replacing the solid pickboard with a grated
   pickboard. Thus, there was no obstruction to the air flow pushing the dust cloud down and away
   from the employee’s breathing zone.
   As a result of testifying as an expert in E. Smalis Painting Co., Inc., 1995-1997 CCH
   OSHD ¶ 31,113 (No. 94-1979, 1996; directed for review), Cignatta prepared a report (Exh. C-
   31). The report and the judge’s decision show that Cignatta anticipated reductions in lead levels
   from an average of 23,000 ug/m3 (three abrasive blaster sampled by OSHA) to less than 500
   ug/m3 with the use of the mini-enclosure and ventilation. However, the record does not show the
   design of the enclosure or describe the air flow pattern for comparison in this case. Also, as noted
   by the judge, the respondent did not present any evidence of infeasibility in the E. Smalis case.
   Although the court is not convinced that employee exposure cannot be improved, the
   record in this case fails to establish that the controls recommended by the Secretary provide
   significant reductions in the employee’s exposure to total dust and lead. Even with engineering
   controls, an employee’s exposure would still significantly exceed the PEL and the employee

                                            18
   

   would still need to wear a Bullard CE type respirator (Tr. 765). Also, the Secretary does not
   discuss the costs of the proposed dance floor or mini-enclosure. The Secretary argues that ACC
   can include the cost of engineering controls when estimating the cost of the project (Secretary’s
   Brief, p. 27). Contractors who do not include regulatory costs in their bids obtain an unfair
   advantage over more responsible contractors. However, the Secretary must identify generally the
   cost of recommended controls. In discussing proof of economic feasibility, the Review
   Commission in Smith Steel Casting Co., 15 BNA OSHC 1001, 1010 (No. 80-2322, 1991), stated
   that the “ Secretary did not have the burden to establish an employer’s cost of compliance to a
   definitive degree of certainty; rather, absent rebuttal evidence, the Secretary was only obligated to
   adduce enough evidence to support a prima facia case.” In Smith Steel Casting Co.,the
   Secretary’s expert used his experience in estimating costs for proposed controls. In this case,
   there should have been at least some general cost information. The alleged violations of §§
   1926.55(b) and 1926.62(e)(1) are vacated.

                     Remaining Violations Alleged in Citation No. 1
     Item 2a and 2b - Alleged violations of §§ 1926.62(h)(5) and 1926.1127(k)(6)
   

   The citation alleges that employees performing abrasive blasting were exposed to lead and
   cadmium when they used compressed air to blow paint chips, dust, and used abrasive from the top
   to the bottom of the abutment. Section 1926.62(h)(5) provides:
   Compressed air shall not be used to remove lead from any surface
   unless the compressed air is used in conjunction with a ventilation
   system designed to capture the airborne dust created by the
   compressed air.

   Similarly, under the cadmium standard, § 1926.1127(k)(6) provides:
   Compressed air shall not be used to remove cadmium from any
   surface unless the compressed air is used in conjunction with a
   ventilation system designed to capture the dust cloud created by the
   compressed air.

   The standards regulate employee exposure to lead and cadmium when using compressed
   air to clean surfaces after abrasive blasting activities. The use of compressed air is permitted to
   clean surfaces if used in conjunction with a ventilation system capable of capturing the resulting
   airborne dust. The purpose is to prevent employee exposure (Tr. 111).

                                            19
   

   It is undisputed that ACC used hoses with compressed air to clean the steel after
   completing the abrasive blasting (Exh. C-3; Tr. 108-109). ACC referred to the operation as
   “blowing down.” After the abrasive blasting, the steel needs to be cleaned of dust particles and
   debris prior to painting. The same employees who did the blasting also performed the cleaning.
   There is no dispute that the dust and paint chips contained lead and cadmium. While preforming
   the blowing down operation, employees wear negative pressure respirators (Exh. R-4; Tr. 181).
   The cleaning was done inside the containment with the tarps in place and the dust collector on and
   pulling air through the structure (Tr. 110).
   The Secretary argues that the dust collector used by ACC did not capture the airborne
   dust created during cleaning. The Secretary claims that ACC’s dust collector was an inadequate
   ventilation system to capture the dust (Secretary’s Brief, p. 30). The Secretary recommends using
   vacuuming to collect the dust as opposed to using an air hose (Tr. 112).
   The record, however, does not support a finding that ACC’s dust collection system was
   inadequate. The Secretary performed no air flow monitoring during the blowing down operation.
   The Secretary’s air monitoring of employees was done during abrasive blasting, not during the
   cleaning process with compressed air. Employees’s exposure levels to lead and cadmium were
   not monitored. There is no showing that the dust collector did not capture the airborne dust
   created during the blowing down operations. The dust collector has 45,000 cfm rated capacity.
   Dan Adley, ACC’s expert, testified that the general dilution system used by ACC was capable of
   capturing particles of dust generated during ACC’s cleaning through the dust collector (Tr. 989-
   990). The violations are vacated.

                   Item 3 - Alleged Violation of § 1926.62(j)(2)(i)(A)
   

   The citation alleges that ACC failed to perform biological monitoring for employees
   exposed to lead concentrations greater than 50 ug/m3 PEL. Section 1926.62(j)(2)(i)(A) requires
   that biological monitoring be performed:
   For each employee covered under paragraph (j)(1)(ii) of this
   section, at least every 2 months for the first 6 months and every 6
   months thereafter;

   Section 1926.62(j) contains the medical surveillance provisions for exposure to lead in
   construction. Section 1926.62(j)(1)(ii) applies to employees “who are or may be exposed by the
   employer at or above the action level for more than 30 days in any consecutive 12 months.” If

                                           20
   

   determined, an employer is required to perform regular biological monitoring in the form of blood
   sampling and analysis for lead and zinc protoporphyrin.
   Nickolas Kofinas, John Manis and Nasos Tataridis, the employees performing abrasive
   blasting, were employed by ACC for more than 30 days in 1996 (Exh. C-23, responses 5, 8, and
   11). ACC does not dispute that the three employees were exposed to lead at or above the action
   level (30 ug/m3) for more than 30 days (Exh. C-23, responses 6, 9, and 12). Kofinas , Manis, and
   Tataridis received blood tests in March, 1996 ,which is the start of the construction season (Exhs.
   C-13, R-10; Tr. 38, 116-117). Manis was retested on October 14, 1996 (Exh. R-10), and Tatridis
   was retested on October 16, 1996 (Exh. C-13). However, there is no showing that Kofinas was
   retested.
   Because the employees were employed by ACC for several years6, ACC is required to
   retest their blood every six months for lead and zinc protoporphyrin. The employees should have
   been retested in September, 1996. ACC does not dispute the violation but seeks to have it
   reclassified as other than serious (ACC Brief, p. 24). ACC argues that the employees wore C. E.
   Bullard positive-air supplied respirators during abrasive blasting and negative pressure respirators
   during non-blasting operations (Exh. R-4; Tr. 181, 200). ACC argues that its failure by two
   weeks to have employees’blood tested for lead did not directly cause any employee exposure to
   serious physical harm or injury.
   The standard requires retesting every six months for permanant employees to determine
   whether an employee’s lead levels are increasing. If an employee’s lead level exceeds 50
   micrograms, the employee is medically removed from the job. By retesting employees, an
   employer has an opportunity to assess its overall lead program and the employee’s work
   practices. By failing to regularly retest, an employee’s lead levels may unexpectedly increase and
   cause lead poisoning. When another employee (Koppos) was retested in October, 1996, his blood
   level exceeded 50 micrograms and he needed to be medically reassigned (Exh. C-13, Tr. 118).
   The violation is affirmed as serious.

                   Item 4a and 4b - Alleged Violation of § 1926.1127(d)(1)(i)
   

   The citation alleges that ACC did not test employees for possible exposure to airborne
   cadmium (Item 4a). The citation also alleges that the designated competent person was not

   6
   Kofinas and Tataridis have been employed by ACC in excess of 15 years (Tr. 338).

                                                   21
   

   capable of identifying hazards associated with cadmium exposure (Item 4b). Section
   1926.1127(d)(1)(i) provides in part that:
   Prior to the performance of any construction work where
   employees may be potentially exposed to cadmium, the employer
   shall establish the applicability of this standard by determining
   whether cadmium is present in the workplace and whether there is
   the possibility that employee exposures will be at or above the
   action level. The employer shall designate a competent person who
   shall make this determination.

   The Secretary argues that ACC failed to determine the potential for cadmium exposure at
   or above the action level of 2.5 ug/m3. A “competent person” is defined at § 1926.1127(b) as a
   “person designated by the employer to act on the employer’s behalf who is capable of identifying
   existing and potential cadmium hazards in the workplace.” Section 1926.1127(d) requires that in
   determining the potential exposure to cadmium, an “investigation shall include a review of
   relevant plans, past reports, material safety data sheets, and other available records, and
   consultations with the property owner and discussions with appropriate individuals and agencies.”
   The Secretary argues that ACC failed to undertake any initial investigation (Secretary’s Brief, p.
   34).

                                          Item 4a
   

   Prior to abrasive blasting, ACC performed a TCLP extraction and air monitoring for lead
   on October 13 at the bridge site (Tr. 125). The TCLP extraction determines whether the residue
   dust that is separated from the reuseable shot can be placed in a regular landfill or whether it must
   be disposed of in a hazardous waste landfill. The test does not determine whether cadmium in a
   surfacing coating will become airborne in the dust generated during abrasive blasting (Tr. 126).
   There was no air monitoring for cadmium.
   ACC does not dispute that cadmium was present in the dust generated during abrasive
   blasting on the Denison Street bridge. The Secretary’s air monitoring found three employees
   (Manis, Kofinas, Tataridis) exposed to cadmium. John Manis’monitoring result was 2.747 mg/m3
   and Nasos Tataridis’monitoring result was 2.984 mg/m3--above the action level of 2.5 ug/m3.
   Nick Kofinas’monitoring result was 2.035 mg/m3 (Exhs. C-4, C-6, C-7).
   Prior to starting the Denison Avenue bridge project, ACC retained Project Teach to
   perform initial air monitoring at the Denision bridge (Tr. 357-358, 1218). Job superintendent

                                            22
   

   Kozanis acknowledges that the samples were not analyzed for cadmium (Tr. 370-371). He
   concedes that it was a mistake (Tr. 341). Also, Harry Koumoundouros, ACC quality control
   supervisor, testified that air monitoring results at other ACC bridge projects in 1996 found the
   presence of lead and cadmium (Tr. 1219, 1228).
   ACC states that it did test for the presence of cadmium in a bulk sample by a TCLP
   extraction. However, an extraction test performed in May, 1995, at another project found
   cadmium levels of 1.2 to 2.8 ug/m3 (Exh. C-14, Tr. 127). ACC argues that the violation for
   failing to test should be vacated or reduced to other than serious because employees wore
   appropriate personal protective equipment (ACC Brief, p. 25).
   The record supports a finding that ACC did not make a determination regarding the
   potential exposure to cadmium. ACC performed no air monitoring or did not show that it
   performed other investigations into the potential for cadmium exposure. The TCLP extraction is
   a bulk sample and was not shown to provide information about the airborne exposure to
   cadmium. The standard requires a determination of the possibility that employee exposure may
   exceed the action level. Also, ACC was aware from monitoring results at other bridge projects of
   the potential for cadmium exposure during abrasive blasting. During a 1995 OSHA inspection,
   air monitoring results found cadmium levels above the action level (Tr. 34).

                                         Item 4b
   

   With regard to the competent person violation, there is no dispute that superintendent
   Kostas Kozanis was ACC’s designated competent person for the Denison Avenue bridge project
   (Tr. 128). To receive his competent person certification, Kozanis attended a specialized course at
   the Steel Structure’s Painting Council (Exh. R-40, p. 26). The Secretary alleges that Kozanis did
   not understand the difference between TCLP extraction results and testing for cadmium which
   could become airborne (Tr. 128).
   Kozanis testified that he receives 40 hours of safety refresher training each year (Tr. 332).
   The training includes annual cadmium training (Tr. 341). He learned during training the PEL for
   cadmium and the minimum air flow rate needed inside the containment was 105 (Tr. 341, 355).
   The cadmium standard contains specific definitions and assigns certain responsibilities to
   the designated competent person. Most importantly, the competent person must be capable of
   identifying the potential for cadmium in the work place. Kozanis’reliance on the TCLP
   extraction results and monitoring done by Project Teach did not relieve him from his

                                           23
   

   responsibilities as a competent person. There was no showing that Project Teach was instructed
   to monitor for cadmium or that the TCLP extraction detected the potential for cadmium as
   required by the standard. Kozanis conceded in fact that no monitoring was performed for
   cadmium. Kozanis did not know what TCLP was or if a test was to be performed (Tr. 363).
   Further, Kozanis had specific knowledge of the potential for cadmium because he was the
   superintendent at a previous bridge project where cadmium exposure was detected (Tr. 34). The
   violation is affirmed.

                     Remaining Violations in Repeat Citation No. 2
                    Item 1c - Alleged Violation of § 1926.62(e)(2)(ii)
   Section 1926.62(e)(2) requires that prior to the commencement of a job, an employer is
   

   required to establish and implement a written compliance program to achieve compliance with the
   PEL requirements for lead exposure. The citation alleges that ACC’s written compliance
   program for lead did not contain certain required elements, including Element B - engineering
   plans and studies used to determine methods selected for controlling exposure; Element C - a
   report of the technology considered in meeting the PEL; Element E - a detailed schedule for
   implementation of the program; and Element H - a description of the arrangements made among
   contractors to inform affected employees of their potential exposure to lead. ACC argues that it
   prepared specific information for Denison bridge project that identifies the lead disturbing
   activities, describes the nature of the activity and specifies engineering controls employed on the
   project. The plan, as described in the Secretary’s preamble, “should be a written strategy and
   schedule for protecting workers from occupational hazards and must incorporate all relevant
   information that relates to those goals, so that one could determine whether the employer
   reasonably analyzed the problems and their solutions, including alternatives.” 58 FR, supra at
   26601 (1993).
   During OSHA’s inspection, superintendent Kozanis produced two documents from a
   binder in his pickup truck, which he identified as ACC’s written lead program (Exhs. C-15, C-16;
   Tr. 132). These documents were entitled “Lead Hazards in Construction” and ACC’s “Worker
   Lead Protection Program.” The documents provided general information about lead and did not
   specifically refer to the Denison Avenue bridge project. However, none of the attachments to
   Appendix A of the “Worker Lead Protection Program” were provided, including “Lead Paint
   Removal Project Specific Requirements” (Exh. C-16). Also, the “Engineering Evaluation” form

                                            24
   

   which was required to be filled out prior to starting the job was not completed (Exh. C-15).
   Kozanis explained his attitude for creating documents, such as the “Lead Paint Removal Project
   Specific Requirements,” when he stated that “I’ve got to have something to show somebody” (Tr.
   357). Additionally, Danann was provided a manufacturer’s brochure for the dust collector and a
   copy of the contractor notification form (Exh. C-17; Tr. 135).
   Element B requires documentation showing the engineering plans and studies used to
   determine methods selected for controlling exposure. ACC’s written program describes the
   nature of the containment used for bridge painting projects. It identifies the need for the dust
   collector (exhaust) and air flow to maintain negative air pressure inside the containment (Exh. C-
   15). The program states that ACC will employ general dilution ventilation through the use of a
   dust collector and air movement at 105 feet per minute (Exh. C-24, p. 2). However, there are no
   studies or plans in ACC documentation showing how or why ACC chose general dilution
   ventilation as its method to control employee lead exposure. ACC’s plan bears no resemblance to
   the containment used at the Denison Avenue bridge or how it intends to achieve the required air
   movement (Exh. C-18). The Federal Highway Administration identified the importance for a
   plan:

          Good linear air flow is essential for low worker exposures. Linear
          air flow can only be achieved with well thought out input and
          exhaust ducts.
   

(“Lead-Containing Paint Removal, Containment and Disposal,” Exh. R-37, p. 66).

ACC’s plan contains no information regarding the method used to determine which controls
would be implemented at Denison Avenue. It does not contain measurements, diagrams,
mathematical formulas and calculations. This is the type of informationn required by Element B.
Such information was provided by ACC at a prior bridge project (Exh. C-19).
In order to satisfy its obligations under Element C and Element E, an employer must have
a report of the technology used to satisfy the PEL requirements and a detailed schedule for
implementing its program. Superintendent Kozanis prepared the pre-job hazard analysis
identifying the controls and implementation plan used at the project (Exh. R-13; Tr. 347). His
analysis identified where the lead hazard was created and the use of recycling equipment, dust
collectors, containment tarps and respirators. It also required the containment to maintain
negative air presssure. Also, ACC relies on the manufacturer’s brochure of the dust collector and

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a report of monitoring (Exhs. R-14, R-15). According to ACC, the dust collector is the “top of
the line” and cost $78,000 (Exh. R-40, p. 24). Although the Secretary does not believe the
engineering controls used by ACC were adequate, the controls used were documented sufficiently
to satisfy the requirements of Elements C and E. The Secretary fails to show how such
documents were deficient. Element H requires a description of the arrangements made with
other contractors. The contractor notificaton form given to Danann was blank (Exh. C-17; Tr.
135). Superintendent Kozanis testified that ACC informed Ruhlin Co., the general contractor, of
the potential for lead exposure (Exh. R-11; Tr. 367-368). The document was received by Ruhlin
Co. on May 11, 1996. In addition to Ruhlin, however, there were other trades working on the
Denison Avenue bridge project, including contractors doing carpentry and concrete removal work
(Tr. 37). There is no showing that the notification was provided to the other contractors. Since it
was ACC’s work which generated the potential lead exposure, ACC retained the responsibility to
assure that all affected employees were informed.
The violation is affirmed as serious in that Elements B and H were not included in ACC’s
written program. The failure to include completed Elements B and H is shown to directly relate
to employee’s health from lead exposure.

                      Item 2 - Alleged Violation of § 1926.62(i)(4)(ii)
   The citation alleges that based on wipe samples from the surface of the lunch table and the

spigot of the water jug, ACC’s eating area was not free as practicable from lead contamination.
Section 1926.62(i)(4)(ii) provides that:

           The employer shall assure that lunchroom facilities or eating areas
           are as free as practicable from lead contamination.

   ACC provided employees with a trailer for eating meals, taking smoke breaks and getting

a drink of water. Before entering the trailer, employees were expected to remove their uniform,
vacuum off their clothes and wash (Tr. 350). According to ACC, the trailer was cleaned by the
quality control person in the morning before the morning break (Tr. 144, 361-362). The quality
control person also was responsible for getting a profile of the steel being blasted, the weather
conditions and temperature, and delivering the material for the blasting operation (Tr. 366-367).
The testimony of Harry Koumondouris, quality control person, is ambiquous and vague as to the
frequency of cleaning the trailer.

                                             26

Q. Who is responsible for cleaning it?
A. The Government is responsible for cleaning the lunch trailer
and the shower trailers, but I made a practice in the past to go
there myself and clean--no clean; check both trailers. If
something is not done properly, I’ll take care of it myself.
Q. At this Denison Avenue, did you have an opportunity to clean
the lunch room or lunch trailer?
A. I went there a couple times, yes.
(Tr. 1217).

    Compliance officer Danann took two wipe samples with dampened filter paper in the

lunch trailer (Tr. 80). The wipe sample from the lunch table showed 0.78 micorgrams of lead per
square centimeter. The spigot to the water jug showed 1.67 micrograms per square centimeter
(Exh. C-5). Danann testified that the spigot was visibly dirty (Tr. 80, 142). The sample results
exceeded the 200 micrograms per square foot (or 0.22 micrograms per square centimeter) as
required by the Housing and Urban Development Guidelines7 for decontamination (Tr. 81-85).
OSHA CPL 2-2.58 recommends the use of HUD’s levels (Tr. 81, 83).
Although “practicable” is not defined in the standard, the dictionary definition is “capable
of being done, effect, or performed; feasible.” Cleaning the meal area at least once a day seems a
reasonable frequency. ACC agrees based on its stated policy (Tr. 361). The use of HUD
guidelines is also a reasonable standard for cleanliness. The Secretary argues that ACC did not
clean its eating areas as often as was feasible (Secretary’s Brief, p. 40).
The violation is affirmed. The ambiquous testimony of the quality control person fails to
show that the trailer was regularly cleaned at least once a day. Based on repeated employee use
for breaks and meals, cleaning the meal area once a day is a minimum reasonable expectation.
ACC’s work on the bridge project was during the days, nights, and on weekends, depending on
the work and need to close traffic lanes on Interstate 71 (Tr. 354). The wipe samples were taken
from the table and spigot. There is no evidence how long the dust had accumulated or when ACC
last cleaned the meal area prior to the wipe samples. The violation is serious in that at least five
employees were exposed, and consumation of lead is one means by which employees are exposed
to potential serious short-term and long-term health affects.

    7
     HUD Guidelines use the unit of square feet (Tr. 81).

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Item 3 - Alleged Violation § 1926.62(l)(1)(iv)
The citation alleges that employees who were exposed to lead at or above the action level
of 30 ug/m3 were not provided annual re-training. Section 1926.62(l)(1)(iv) provides that:
The employer shall also provide the training program at least
annually for each employee who is subject to lead exposure at or
above the action level on any day.

     The standard requires annual lead training for employees. Section 1926.62(l)(2) identifies

eight topics on which employees must be trained. ACC acknowledges that Nick Kofinas, an
employee performing abrasive blasting, did not receive training in 1996 (Exh. C-21, Para 7). On
October 26, 1996, Kofinas’lead exposure was 1963 ug/m3, 65 times above the 30 ug/m3 action
level.
ACC argues that it maintains a comprehensive lead training program for employees which
is conducted in the spring of each year (Exh. R-40, p. 27; ACC Brief, p. 29). The training
program consists of a review of the lead standard requirements. The employees also receive their
initial physical examinations, blood tests and respirator fit tests (Exhs. C-15, C-16, R-40, p. 26-
27). The training is conducted at the commencement of the construction season in the spring. If
unable to attend the initial training session, employees are supposed to receive the training when
first reporting to work (Exh. R-40, p. 29). According to ACC, employees who miss the March
training session receive it at the worksite.
The violation is affirmed. There is no dispute that at least one employee did not receive
the annual training in 1996. The failure to provide Kofinas lead training in 1996 indicates a
weakness in ACC’s training program. It shows a deficiency in ACC’s monitoring of its training
programs. ACC is a small employer with less than 15 employees (Tr. 301).
The violation, however, is other than serious because only Kofinas was not trained in
1996. There is no evidence that Kofinas, who had been employed by ACC for 25 years, was not
trained in the prior years (Tr. 338). The missed 1996 training may have merely reinforced
Kofinas’s previous training. Kofinas was not a witness.

                             Repeat Consideration for Citation 2



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The violations alleged in Citation No. 2 were classified as repeat violations. The
Secretary’s basis for alleging repeat violations is previous citations issued on January 28, 1994, to
Atlas-Scordos Painting, Inc., a bridge painting company with Nick Pontikos as president (Exh. C-
20). The citations became a final order of the Review Commission on July 25, 1994.
A violation is a repeated violation if, at the time of the violation, there was a Commisssion
final order against the same employer for a substantially similar violation. Potlatch Corp., 7 BNA
OSHC 1061, 1063 (No. 16183, 1979). Unless the violation involves a general standard, the
Secretary establishes substantial similarity by showing that both violations are of the same
standard. Monitor Constr. Co., 16 BNA OSHC 1589, 1594 (No. 91-1807, 1994).
There is no dispute that the same standards were previously violated and became a final
order of the Review Commission. The issue is whether the citations were issued to the same
employer. The Secretary argues that repeat violations are established because of the
commonalities between Atlas Central Corporation and Atlas-Scordos Painting, Inc.
“Only an employer may be cited for a violation of the Act.” Vergona Crane Co., 15 BNA
OSHC 1782, 1783 (No. 88-1745, 1992). Section 3(5) of the Act defines an employer as “a
person engaged in a business affecting commerce who has employees.” Section 3(4) defines a
person as “one or more individuals, partnerships, assiciations, corporations, business trusts, legal
representatives, or any organized group of persons.”
ACC is a corporation with Nick Pontikos as president and owner (Tr. 30, 133-134, 328).
Atlas-Scordos Painting, Inc., is also as a corporation and apparantly was a joint venture between
Nick Pontikos and Mike Scordos as presidents (Tr. 328). Bill Pontikos is the secretary-treasurer
for both companies (Tr. 30, 328). Both ACC and Atlas-Scordos Painting, Inc., are in the bridge
painting business (Tr. 30). Compliance officer Danann had inspected Atlas-Scordos three times
(two sites in 1993 and one site in 1995). When she inspected Atlas-Scordos in 1995,
superintendent Kozanis was working as the foreman on the project. Cathy Royle, the health and
safety director of ACC, was directing lead compliance activities. Also, during the inspection,
Atlas-Scordos and ACC shared office space and were located at the same address (Tr. 30-31).
The Secretary argues that the two business should be treated as a single employer for the
repeat classification because the two entities have common ownership and officers and were
engaged in the same type of business. NLRB v. Patterson Menhaden Corp., 389 F.2d 701 (5th
Cir. 1968). The Secretary’s argument is misplaced. Unlike the willful classification, which
requires a showing of an employer’s knowledge and intent, the repeat classification by definition

                                             29

is limited to the same employer. ACC and Atlas-Scordos are different legal entities and can not
be considered as the same employer for the purposes of a repeat classification.

                            Other Than Serious Citation No. 3
                 Item 1 - Alleged Violation of § 1926.1127(m)(4)(iii)(A)
   The citation alleges that ACC’s cadmium training did not identify lung cancer as a

potential long-term health effect. Section 1926.1127(m)(4)(iii)(A) provides:
(iii) The employer shall make the training program understandable
to the employee and shall assure that each employee is informed of
the following:
(A) The health hazards associated with cadmium
exposure, with special attention to the information
incorporated in appendix A to this section;

   An employer’s cadmium training program is required to inform employees of the health

hazards associated with cadmium exposure. Appendix A to the standard provides the information
contained on the safety data sheet, including the potential health hazards from short-term (acute)
and long-term (chronic) exposures. The long-term exposure warns that “repeated or long-term
exposure to cadmium, even at relatively low concentrations, may result in kidney damage and an
increased risk of cancer of the lungs and the prostate.”
The record shows that three employees (Manis, Kofinas, Tataridis) performing abrasive
blasting were exposed to cadmium; two employees were exposed above the action level of 2.5
ug/m3 (Exhs. C-4, C-6, C-7). Thus, the employees should have been informed of the cancer risk
associated with cadmium exposure. A review of ACC’s written safety program “Cadmium Safety
In Construction” shows no specific reference to the potential risk of lung cancer (Exh. C-22; Tr.
150). However, the program does review in some detail the nature of cadmium, how exposure
occurs, cadmium’s action level and the PEL, and certain health hazard information of short-term
and long-term effects. Under long-term effects, the program describes that the exposure to
cadmium has caused an increase in cancer hazards, including cancer of the prostate (Exh. C-22, p.
2-3). ACC argues that OSHA’s citation is “nit picking” (ACC Brief, p. 30).
The court disagrees. The standard requires that employees be informed of the potential
health hazards associated with exposure to cadmium. It directs that special attention be given to
the health hazards identified in Appendix A. ACC’s program fails to identify lung cancer as a
potential health hazard. Based on the nature of employee exposure, it is more important that

                                            30

ACC inform employees of the potential for lung cancer. ACC’s employees regularly work in
areas of high dust concentrations which potentially contain airborne cadmium. Inhalation and
swallowing are the means of exposure. Therefore, the potential for lung cancer reinforces the
employees’need to wear appropriate respiratory equipment. There is no showing that ACC
informed employees of the potential of lung cancer. The violation is affirmed.

                      Penalty Considerations for Citation Nos. 1 and 2
   The Commission is the final arbiter of penalties in all contested cases. In determining an

appropriate penalty, the Commission is required to consider the size of the employer’s business,
history of previous violations, the employer’s good faith, and the gravity of the violation. Gravity
is the principal factor to be considered.
ACC is entitled to credit for size and good faith. ACC is a small employer with less than
15 employees (Tr. 301). Also, ACC maintained appropriate health and safety programs which
were, for the most part, adequate (Tr. 302). ACC is not entitled to credit for history because
ACC has been previously cited for serious violations (Tr. 152).

Serious Citation No. 1
A penalty of $625 is reasonable for failing to perform biological monitoring as required by
§ 1926.62(j)(2)(i)(A) (Item 3). The three employees performing abrasive blasting were exposed
to extremely high levels of airborne concentrations of lead. One employee did not receive a blood
test in 1996 and the other employees did not receive blood tests within the six-month frequency
set by the Secretary. However, the employees wore appropriate personal protective equipment,
including an air flow respirator.
A penalty of $625 for violation of § 1926.1127(d)(1)(i) (Items 4a and 4b) is reasonable for
failing to determine the presence of cadmium in the workplace. At least two employees were
exposed above the action level for cadmium.

Repeat Citation No. 2
A penalty of $625 for serious violation of § 1926.62(e)(2)(ii) (item 1c) is reasonable. A
written control plan is necessary to show compliance with the PEL requirements for lead
exposure.

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A penalty of $625 for serious violation of § 1926.62(i)(4)(ii) (item 2) is reasonable.
ACC’s cleaning in the meal trailer was not shown to be regular or adequate. The wipe samples
showed excessive amounts of lead contamination on the table where employees ate and from the
spigot used by employees to obtain water. At least five employees working at the Denison
Avenue bridge project were exposed to accumulations of lead in the trailer.

                               FINDINGS OF FACT AND
                               CONCLUSIONS OF LAW

    The foregoing decision constitutes the findings of fact and conclusions of law in

accordance with Rule 52(a) of the Federal Rules of Civil Procedure.

                                          ORDER
    Based upon the foregoing decision, it is ORDERED that:

Serious Citation No. 1:
1. Item 1a, violation of § 1926.55(a), and item 1b,violation of § 1926.55(b), are
vacated.
2. Item 2a, violation of § 1926.62(h)(5), and item 2b, violation of § 1926.1127(k)(6),
are vacated.
3. Item 3, violation of §1926.62(j)(2)(i)(A), is affirmed and a penalty of $625 is
assessed.
4. Item 4a, violation of § 1926.1127(d)(1)(i), and item 4b, violation of §
1926.1127(d)(1)(i), are affirmed and a grouped penalty of $625 is assessed.

Repeat Citation No. 2:
1. Item 1a, violation of § 1926.62(c)(1), and item 1b, violation of § 1926.62(e)(1),
are vacated.
2. Item 1c, violation of § 1926.62(e)(2)(ii), is affirmed as serious and a penalty of
$625 is assessed.
3. Item 2, violation of § 1926.62(i)(4)(ii), is affirmed as serious and a penalty of $625
is assessed.

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3. Item 3, violation of § 1926.62(l)(1)(iv), is affirmed as other than serious and no
penalty is assessed.

Other Than Serious Citation No. 3
1. Item 1, violation of § 1926.1127(m)(4)(iii)(A), is affirmed and no penalty is
assessed.

                                  KEN S. WELSCH
                                  Judge

Date: February 15, 1999

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