FOUNDRY

HEALTH AND
SAFETY
HOT WORKING OF METALS
 Molten Facts
How
Barely Hot Hot Very Hot Too Hot
to?

Temp Below 1000F 1000F-1500F 1500F-2250F 2250F or Higher

Brass,
Tin, Lead, Aluminum Bronze, Gold,
Metal Iron, Steel
Zinc (786F) 1220 F Silver or
Copper
These alloys can Electric Induction
be melted on the Aluminum can furnaces are used
stove in a soup be melted in a for large
can. coffee can on A gas or electric commercial
Tools Caution: Most low- the BBQ, use crucible furnace foundries.
melting alloys are propane, wood is typical. Cupola furnaces
TOXIC, vent well or charcoal for use coke (refined
and use a fuel. coal) for smaller
respirator. batches.

Thick shirt and

Safety Gloves and pants. "Going into a
Safety Glasses
needs Glasses Glasses and volcano" suit !
gloves.
 Hazardous Materials
• Dusts, solvents, and other materials present a health
hazard in foundries.
• Dust is generated in many foundry processes and
presents a twofold problem:
1) Cleaning to remove deposits
2) Control at the point of origin to prevent further dispersion and
accumulation
• Vacuum cleaning is the best way to remove dust in foundries.
• Once dust has been removed, prevent further accumulation by using
local exhaust systems (LEV) that remove it at the point of origin.
 Hazardous Materials (Cont.)
• Solvents: evaluate each solvent on the basis of its
chemical ingredients
• Proper labeling, substituting less hazardous for more hazardous
chemicals, limiting the quantities in use, and using other methods
of control can help minimize the toxic and flammable hazards
involved in using solvents.
• Other materials: many metal resins, and other substances
present safety and health hazards
 Hazardous Materials (Cont.)
• Other hazardous materials that are found in various
stages and locations of hot metal operations include:
• acrolein
• beryllium
• carbon as sea coal
• carbon monoxide (CO)
• chromium
• fluorides
• lead
• magnesium dust or chips
• manganese
• phosphorus
• resins and resin dusts
• silica
• sulfur dioxide
 Hazardous Materials (Cont.)
• Iron-oxide: fumes and dusts
are created during melting,
burning, pouring, grinding,
welding, and machining of
ferrous castings
• Use LEV to vent these fumes.
 Medical Program
• Baseline physical examinations, including chest x-rays,
audiometric tests, and pulmonary function tests
• Periodic physical examinations to detect incipient disease
and to help reclassify workers as needed
• Adequate first aid facilities and employee training in first
aid
• Observe regulatory requirements if respirators must be
worn
• Industrial hygiene monitoring where needed
 Personnel Facilities
• Encourage frequent washing with soap and water, and
install adequate facilities.
• Coreroom workers whose hands and arms may be exposed to
sand and core oil mixtures are candidates for dermatitis.
• Prolonged contact with oil, grease, acids, alkalis, and dirt can
produce dermatitis.
• Reference industrial sanitation standards.
• Sanitary food preparation and service is especially
important in nonferrous foundries.
• Prohibit eating in work areas.
 Work Environment in Foundries
• Good housekeeping, ventilation, and light help maintain a
safe and healthy work environment.
• Proper inspections, maintenance, and fire protection
increase workers’ safety in foundries.
• Housekeeping
• Clean machines and equipment after each shift, and keep them
reasonably clean during the shift.
• Place all trash in the proper trash bins.
• Keep the floors and aisles in the work area unobstructed.
• Properly stack and store materials.
• Observe floor loading limits
Work Environment in Foundries (Cont.)
• Noise control
• Controlling excessive levels of noise, more than 85dBA, may
sometimes be difficult.
• Engineering is not always possible because of a lack of technology
or is impractical.
• Develop a hearing conservation program that provides approved
hearing protection for each worker.
• Minimize exposure to identified high-noise-level hazards.
Work Environment in Foundries (Cont.)
• Lighting
• Good lighting is difficult to achieve.
• Where craneways are used, light fixtures must be placed high and
at considerable distances from work areas.
• Nevertheless provide good lighting for each work area.
Work Environment in Foundries (Cont.)
• Inspection and maintenance
• Follow standard inspection and maintenance procedures in
foundries.
• Carefully select maintenance personnel.
• Train them in safe practices, especially in procedures for locking
out controls and isolating other energy sources.
Work Environment in Foundries (Cont.)
• Fire protection
• Make periodic fire inspections.
• Perform emergency fire fighting drills.
• If a fire brigade is present, it will aid the safety program by keeping
its members, as well as other employees in the foundry, safety
conscious.
Work Environment in Foundries (Cont.)
• Facility structures
• Entrances and exits—all doors should have an eye-level window
opening.
• Stairways: provide handrails, standard guardrails, and toeboards
for stairs having four or more risers.
• Floors and pits: install special types of flooring where explosion
hazards exists; keep clean and dry.
• Galleries: provide galleries with solid, leak-proof floors.
• Gangways and aisles: should be firm enough to withstand daily
traffic.