OSHA Cites Foundry after Worker 'Incinerated' on 9th Day on Job

Mapleton, IL (WorkersCompensation.com) - An Illinois foundry is facing a six-figure penalty after federal investigators found an employee died immediately after he fell into a vat of molten iron. 

According to a press release from the U.S. Department of Labor, Occupational Health and Safety Administration investigators found that Caterpillar of Irving, Texas was responsible when a 39-year-old died on his ninth day on the job. Caterpillar is one of the world's largest manufacturers of industrial vehicles and equipment. The company operates the foundry which produces cast iron engine components. 

OSHA investigators were called to the foundry in June when the employee died after falling into an 11-foot deep pot of molten iron heated to more than 2,600 degrees Fahrenheit. The worker, Steven Dierkes, of Peoria, Ill., was removing a sample of iron from the furnace when he fell in. Investigators said he was immediately incinerated, leaving half of his body on the floor next to the pot.

According to the U.S. Bureau of Labor Statistics, new employees are five times more likely to be injured on the job than experienced workers. The bureau said 40 percent of all injuries involve people who have been on the job for less than 12 months. Additionally, the bureau said, one in eight injuries happens on an employee's first day. 

But, OSHA investigators said, Dierkes' death could have been prevented had Caterpillar installed fall protections. 

"A worker's life could have been spared if Caterpillar had made sure required safety protections were in place, a fact that only adds to this tragedy," said OSHA Regional Administrator Bill Donovan in Chicago. "Producing more than 150,000 tons each year, Caterpillar's foundry is one of the nation's largest and they should be acutely aware of industry regulations to protect workers using smelters and other dangerous equipment." 

Federal regulations require that employers install guardrails or restraint systems, or to cover hazards to protect workers from falls into dangerous equipment. 

The company was cited for one willful violation, and OSHA proposed a fine of $145,027. In its report, OSHA said the company failed to ensure that employees less than four feet above dangerous equipment were protected from falling into or onto the vat. Specifically, the agency said, employees were exposed to unprotected fall hazards into Melter #1, Melter #2, and Melter #3, across three shifts a day which exposed employees Taking temperature readings, taking button samples, taking thermal cups, and adding alloy bags directly to the melters to hazards.

"Caterpillar's failure to meet its legal responsibilities to ensure the safety and health of workers leaves this worker's family, friends and co-workers to grieve needlessly," said OSHA Area Director Christine Zortman in Peoria. "We implore employers to review the agency specific regulations to protect workers from falls into equipment in industrial settings." 

Caterpillar has more than 800 workers at the foundry, which provides engine components for construction and mining equipment, off-highway diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. According to the company's website, the foundry goes through 1,000 tons of iron a day. 

The company said it was “deeply saddened” by Dierkes’ death.

“Our thoughts remain with this employee’s family, friends and colleagues,”  a spokesperson for the company said in a statemen continued. “The safety of our employees, contractors and visitors is our top priority at all Caterpillar locations around the world. Regarding the serious safety incident that occurred, we will continue to engage with OSHA to seek an appropriate resolution to its review.”

Dierkes accident was the second major accident at the Mapleton location in less than a year. In December 2021, Peoria Sheriff's Office deputies were called to the plant when a worker fell from a "significant height" and died.

Scott Adams, 50, also of Peoria, was pronounced dead on December 23, when he fell through a hole in the floor. OSHA investigators filed preliminary findings that Adams had stepped off of a ladder prior to falling 20 feet to his death. 

"We are deeply saddened by the death of a third-party service provider employee who was involved in an accident in our Mapleton facility on December 23," the company said in a statement at the time. "Our thoughts are with the worker’s family, friends and colleagues. We strive each day to have a safe workspace for our employees, contractors and visitors. As this accident is currently under review, we are not able to provide any additional information at this time." 

Caterpillar has 15 business day to comply with OSHA penalties in Dierkes case, or to contest it, OSHA said. The company can request an informal conference with the agency's area director or contest the findings before an independent review commission.

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