ANNUAL SUMMARY MOLTEN METAL INCIDENTS FOR 2012 April 2014

Incidents by Year 1981 to 2012 – Total 2974 FIGURE 1. INCIDENTS REPORTED FOR THE PERIOD 1981 – 2012 April 2014

Incidents by Force Level 1981 to 2012 – Total 2974 FIGURE 2. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

Incidents by Force Levels 2 & to 2012 FIGURE 3. INCIDENTS BY FORCE LEVELS 2 & 3 FOR THE PERIOD 1981 – 2012 April 2014

Force 3 Incidents Only 1981 to 2012 FIGURE 4. FORCE 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

Force 2 & 3 Incidents 1981 to 2012 FIGURE 5. FORCE 2 & 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014 Linear (Force 2: 2000 – 2012) Linear (Force 3: 2000 – 2012) R² = R² =

Incidents by Force Level 1981 to 2012 – Total 2974 FIGURE 6. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

All Force Levels by Percentage FIGURE 7. ALL FORCE LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

Injuries from Incidents 1981 to 2012 (Total 1422 Injuries) FIGURE 8. INJURIES FROM INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

Injuries by Severity – Total to 2012

Injury Levels by Percentage FIGURE 10. INJURY LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

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

Fatalities from Explosions 1981 to 2012 FIGURE 12: FATALITIES FROM EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

Force Level Incidents by Operation FIGURE 13. FORCE LEVEL INCIDENTS BY OPERATION FOR THE PERIOD 2012 April 2014

Force Level Explosions by Operation 1980 to 2012 FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014

13 Melting Explosions FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014 Causes: Wet / Cold Charge, Tool or Salt

FIGURE 16. MELTING EXPPOSIONS BY CHARGE MATERIAL FOR 1980 – 2012 April 2014 Melting Explosions - Charge Material Involved

24 Casting Explosions FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014

DC/HDC/EMC Explosions by Cast Segment 1980 to 2012 FIGURE 18. CASTING EXPLOSIONS by CAST SEGMENT FOR 1981 – 2012 April 2014

Major Causes of 24 Casting Incidents 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 FIGURE 20. CAUSES OF TRANSFER EXPLOSIONS FOR 2012 April Wet Troughing (Force 2) 1 - Wet Spout (Force 1) 1 - Wet Pan (Force 1)

FIGURE 21: TRANSFER EXPLOSIONS by EQUIPMENT FOR April 2014 Transfer Explosions by Equipment – Total to 2012

FIGURE 22. INJURIES BY OPERATION FOR 2012 April 2014 Note: All Injuries in ‘Other’ Category were in REDUCTION Process 23 Injuries by Operation

FIGURE 23. INJURIES BY OPERATION April 2014 Injuries by Operation –

Force Level by Process Plant FIGURE 24. FORCE LEVEL BY PROCESS PLANT REPORTED FOR 2012 April 2014

Force Level by Process Plant 1980 to 2012 FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014

FIGURE 26. REDUCTION PLANT INJURIES BY OPERATION FOR 2012 April 2014 Causes of Reduction Explosions: Wet / Damp Tools & Samplers Damp Wood Poles Wet /Damp Metal Charged into Pot Reduction Plant Injuries

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

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

Injury Severity by Process Plant FIGURE 29. INJURY SEVERITY BY PROCESS PLANT FOR 2012 April 2014

Injury Severity by Process Plant 1980 to 2012 FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014