ANNUAL SUMMARY MOLTEN METAL INCIDENTS

FOR 2012April 2014

Incidents by Year1981 to 2012 – Total 2974

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

2003

2005

2007

2009

2011

0

20

40

60

80

100

120

140

160

180

200

FIGURE 1. INCIDENTS REPORTED FOR THE PERIOD 1981 – 2012 April 2014

Incidents by Force Level 1981 to 2012 – Total 2974

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

2003

2005

2007

2009

2011

0

20

40

60

80

100

120

140

160

Force 1

Force 2

Force 3

FIGURE 2. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

Incidents by Force Levels 2 & 3 1981 to 2012

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

2003

2005

2007

2009

2011

0

5

10

15

20

25

30

35

40

45Force 2

Force 3

Avg.# Force 2/yr - 24

FIGURE 3. INCIDENTS BY FORCE LEVELS 2 & 3 FOR THE PERIOD 1981 – 2012 April 2014

Force 3 Incidents Only1981 to 2012

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

2003

2005

2007

2009

2011

0

1

2

3

4

5

6

7

8

9

Force 3

Avg # Force 3 Explosions/Yr

FIGURE 4. FORCE 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

Force 2 & 3 Incidents1981 to 2012

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

2003

2005

2007

2009

2011

0

5

10

15

20

25

30

35

40

45

Force 2

Force 3

FIGURE 5. FORCE 2 & 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

Linear (Force 2: 2000 – 2012)Linear (Force 3: 2000 – 2012)

R² = 0.5453

R² = 0.8132

Incidents by Force Level1981 to 2012 – Total 2974

Force 1 Force 2 Force 3

Series1 2102 NaN 759 NaN 113

250

750

1250

1750

2250

Chart Title

FIGURE 6. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

70.7%

25.5%3.8%

Force 1

Force 2

Force 3

All Force Levels by Percentage1981 - 2012

FIGURE 7. ALL FORCE LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

Injuries from Incidents1981 to 2012 (Total 1422 Injuries)

0

10

20

30

40

50

60

70

80

90

100

Minor

Serious

Fatal

FIGURE 8. INJURIES FROM INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

Injuries by Severity – Total 14221981 to 2012

Minor Serious Fatal

Series1 964 NaN 368 NaN 90

50

150

250

350

450

550

650

750

850

950Chart Title

FIGURE 9. INJURIES BY SEVERITY FOR THE PERIOD 1981 – 2012 April 2014

68.0%

26.0%6.0%

Minor

Serious

Fatal

Injury Levels by Percentage1981 - 2012

FIGURE 10. INJURY LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

Injury Risk per 100 Explosions1980 - 2012

FIGURE 11. INJURY RISK PER 100 EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

Minor Serious Fatal

%Injury / 100 Explo-sions

0.32 0.12 0.03

3%

8%

13%

18%

23%

28%

33%

Fatalities from Explosions1981 to 2012

19821984

19861988

19901992

19941996

19982000

20022004

20062008

20102012

0

2

4

6

8

10

12

14

16

18

20

Fatals

Avg # of Fatalities - 2.8/yr

FIGURE 12: FATALITIES FROM EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

Force Level Incidents by Operation - 2012

Melting Casting Transfer Other

Force 1 11 22 2 17

Force 2 3 2 1 0

Force 3 0 0 0 0

2.5

7.5

12.5

17.5

22.5Note: All Explo-

sions in ‘OTHER’ Category were in

REDUCTION Process

FIGURE 13. FORCE LEVEL INCIDENTS BY OPERATION FOR THE PERIOD 2012 April 2014

Force Level Explosions by Operation1980 to 2012

Melting Casting Transfer Other

Force 1 641 725 514 232

Force 2 356 232 150 23

Force 3 79 17 9 8

50150250350450550650750

FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014

13 Melting Explosions - 2012

ScrapCharge

Sow Charge

RSI Charge

Alloying Mg Stirring Salt Charge

Force 1 6 1 1 1 0 1

Force 2 2 0 0 0 1 0

Force 3 0 0 0 0 0 0

0.5

1.5

2.5

3.5

4.5

5.5

FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014

Causes: Wet / Cold Charge, Tool or Salt

Scrap Sow Alloy Adds

Ingot /Tbar

Other Scrap / Sow

Force 1 279 77 107 52 26 12

Force 2 189 51 19 40 13 7

Force 3 52 9 4 0 3 2

25

75

125

175

225

275

FIGURE 16. MELTING EXPPOSIONS BY CHARGE MATERIAL FOR 1980 – 2012 April 2014

Melting Explosions - Charge Material Involved1980 - 2012

24 Casting Explosions - 2012

Start-up Steady State

Termina-tion

DC Slab / Bil-let

Rod Sow or Mold

Force 1 12 3 7 NaN 13 3 6

Force 2 1 1 0 NaN 2 0 0

Force 3 0 0 0 NaN 0 0 0

1

3

5

7

9

11

13

FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014

DC/HDC/EMC Explosions by Cast Segment 1980 to 2012

Start- up

SteadyState

Termina-tion

# of Explo-sions

553 107 73

50

150

250

350

450

550

FIGURE 18. CASTING EXPLOSIONS by CAST SEGMENT FOR 1981 – 2012 April 2014

Major Causes of 24 Casting Incidents - 2012

FIGURE 19: MAJOR CAUSES OF CASTING INCIDENTS FOR 2012 April 2014

DC Start-up Issues: Wet / Damp Starting Blocks, Water Control Problems, Equipment Malfunction, Metal Level Control, Recipe Problems, Metal Temperature Control

DC Steady-State Issues: Low Water Abort / Ingot Head Below Mold

DC Termination Issues: Wet / Damp Drain Pan

Rod Casting Issues: Broken Spout, Wet / Damp Degasser

Sow Casting Issues: Damp / Cold Molds & Tools, Delays, Equipment Malfunction

Causes of 3 Transfer Explosions - 2012

FIGURE 20. CAUSES OF TRANSFER EXPLOSIONS FOR 2012 April 2014

1 - Wet Troughing (Force 2)1 - Wet Spout (Force 1)1 - Wet Pan (Force 1)

FIGURE 21: TRANSFER EXPLOSIONS by EQUIPMENT FOR 1980 - 2012 April 2014

DrainPan

Trough Cruci-ble

Other

# of Explosions 286 185 109 93

25

75

125

175

225

275

Transfer Explosions by Equipment – Total 6731980 to 2012

Melting Casting Transfer Other

Minor 0 3 2 17

Serious 0 1 0 0

Fatals 0 0 0 0

13579

11131517

FIGURE 22. INJURIES BY OPERATION FOR 2012 April 2014

Note: All Injuries in ‘Other’ Category were

in REDUCTION Process

23 Injuries by Operation - 2012

Melting Casting Transfer Other

Minor 241 341 241 155

Serious 116 159 77 16

Fatals 59 21 7 3

25

75

125

175

225

275

325

FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014

Injuries by Operation – 1980 - 2012

Force Level by Process Plant - 2012

Reduction Extrusion Rolling Recycling

Force 1 39 2 6 5

Force 2 1 0 3 2

Force 3 0 0 0 0

2.57.5

12.517.522.527.532.537.5

FIGURE 24. FORCE LEVEL BY PROCESS PLANT REPORTED FOR 2012 April 2014

Force Level by Process Plant 1980 to 2012

Reduction

Extrusion

Rolling

Recycling

Foundry

Atomizing

Alloying

BRW Other R&D

Force 1 1182 230 646 183 28 11 9 12 2 34

Force 2 268 109 418 125 19 6 6 9 2 13

Force 3 25 17 210 36 9 0 0 2 0 0

100

300

500

700

900

1100

FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014

Melting Casting Transfer Other

Minor 0 1 1 15

Serious 0 0 0 0

Fatals 0 0 0 0

1

3

5

7

9

11

13

15

FIGURE 26. REDUCTION PLANT INJURIES BY OPERATION FOR 2012 April 2014

Causes of Reduction Explosions:Wet / Damp Tools & Samplers

Damp Wood PolesWet /Damp Metal Charged into Pot

Reduction Plant Injuries - 2012

Melting Casting Transfer Other

Minor 0 2 0 0

Serious 0 1 0 0

Fatals 0 0 0 0

0.5

1.5

FIGURE 27. ROLLING PLANT INJURIES BY OPERATION FOR 2012 April 2014

Rolling Plant Injuries - 2012

Melting Casting Transfer Other

Minor 0 0 1 0

Serious 0 0 0 0

Fatals 0 0 0 0

0.5

FIGURE 28. EXTRUSIONS PLANT INJURIES BY OPERATION FOR 2012 April 2014

Extrusion Plant Injuries - 2012

Injury Severity by Process Plant - 2012

Reduction Extrusion Rolling Recycling

Minor 19 1 2 0

Serious 0 0 1 0

Fatals 0 0 0 0

2.5

7.5

12.5

17.5

FIGURE 29. INJURY SEVERITY BY PROCESS PLANT FOR 2012 April 2014

Injury Severity by Process Plant 1980 to 2012

Reduction

Extrusion

Rolling

Recycling

Foundry

Atomizing

Alloying

BRW Other R&D

Minor 471 121 175 100 82 0 2 9 6 12

Serious 110 65 83 71 34 2 1 1 0 1

Fatals 12 16 14 29 19 0 0 0 0 0

50

150

250

350

450

FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014