foundries- worksafe no. 1 (2008)

7/30/2019 Foundries- Worksafe No. 1 (2008)

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Edition No. 1September 2008

Compliance code

Foundries


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Preface 1

Introduction 2

Purpose 2

Scope 2

Application 3

Duties 3

Controlling OHS hazards and risks 4Hierarchy of control 5

Consultation 5

Foundry hazards and controls 6

Molten metal explosions 6

Heat stress 7

Burns 9

Light radiation 9

Hazardous substances 9

Dangerous goods 15

Slips, trips and falls 16

Manual handling 16

Machinery and equipment (plant) 17

Working with molten metal 22

Foundry layout 22

Furnaces 25

Furnace tools 25

Raw material inspection 26

Charging metal into the furnace 27

Dross 29Moving molten metal 30

Slagging 31

Tapping and pouring (casting) 31

Molten metal spills 32

Housekeeping 33

Personal protective equipment in the foundry 35

Storage and care of protective equipment 38

Appendix A: The compliance framework 40

Appendix B: Definitions 41

Appendix C: Consultation 42

Appendix D: Hazardous substances: exposure

standards, atmospheric monitoring

and health surveillance 43

Appendix E: Dangerous goods in foundry

operations 46

Appendix F: Effective PPE program 47

Appendix G: Further information 50

Contents

WorkSafe Victoria is a trading nameof the Victorian WorkCover Authority.

This publication is protected bycopyright. WorkSafe encourages the

free transfer, copying and printingof this publication if such activitiessupport the purpose and intent forwhich this publication was developed.


3/56WorkSafe Victoria Compliance code /Foundries 1

This compliance code provides practical guidance to those who have duties under

the Occupational Health and Saety Act 2004 (the OHS Act) or Occupational Healthand Saety Regulations 2007 (the Regulations). It shows how to comply with thoseduties or obligations.

It was made under the OHS Act and was approved by The Hon. Tim Holding MP,Minister or Finance, WorkCover and the Transport Accident Commission, on19 September 2008.

This compliance code has been developed by WorkSae Victoria. Representatives oemployers, employees and government agencies were consulted during its preparation.

Employers, employees, sel-employed persons and those with management andcontrol o workplaces need to use the compliance code in conjunction with theAct and Regulations.

This compliance code is not mandatory. A relevant duty holder who complieswith the compliance code will to the extent the compliance code deals withtheir duties or obligations under the OHS Act and Regulations be consideredto have complied with their duties and obligations.

I conditions at the workplace or the way work is done raise dierent or additionalrisks not covered by the compliance code, compliance needs to be achieved byanother means.

WorkSae publishes guidance to assist with this process at worksafe.vic.gov.au.

Evidence o a ailure to observe a compliance code may be used as evidence inproceedings or an oence under the OHS Act or Regulations. However, a dutyholder will not ail to meet their duty or obligation simply because o a ailure toobserve a compliance code.

A WorkSae inspector may cite a compliance code in a direction or condition inan improvement notice or a prohibition notice as a means o achieving compliance.

A health and saety representative (HSR) may cite a compliance code in a provisionalimprovement notice when providing directions as to how to remedy an allegedcontravention o the OHS Act or Regulations.

The approval o a compliance code may be varied or revoked by the Minister. Toconfrm that this compliance code is current and in orce, go to worksafe.vic.gov.au.

Preface


4/562 Compliance code /Foundries WorkSafe Victoria

Purpose

1. The purpose o this compliance code is to provide practical guidance onhow employers who undertake oundry work can meet their duties under theOccupational Health and Saety Act 2004 (the OHS Act) and OccupationalHealth and Saety Regulations 2007 (the Regulations).

Scope

2. This code covers oundry work that predominantly involves the castingo molten metal into a mould. It can be done manually (static casting) orautomatically (injection, die or continuous casting). A typical process includespreparing a mould casting, melting and pouring metal into the mould, andremoving and fnishing the casting.

3. Because o the diverse and hazardous nature o the work environment,oundries present a range o risks, including:

explosionandburnsfrommoltenmetal

respiratorydisordersfromexposuretogases,vapours,fumesanddusts

effectsonskinfromcontactwithcorrosivechemicals

eyeinjuriesfromlightradiation,metalfragmentsorchemicalsplashes

heatstress,heatstrokeandfatiguefromhotworkingconditions

slips,tripsandfalls

jointandmusclesprainsandstrains

mechanicalhazardsfrommachineryandequipment(suchasentanglement

or crushing) non-mechanicalhazardsfrommachineryandequipment(suchasvibrationand noise).

4. The code provides practical guidance on oundry specifc hazards but alsoreers to other hazards related to oundry work. Risk controls set out in theboxes throughout the code are considered to be one means o meeting a dutyholders obligations so ar as is reasonably practicable. I the risk controls arenot appropriate to the particular circumstances in a oundry, a duty holderis expected to implement equally eective controls by applying the approachshown in paragraphs 1316. Where hazards are subject to specifc regulation(eg hazardous substances), the specifc regulation should be relied on orcompliance to be achieved.

Introduction



Application

5. This compliance code is primarily aimed at employers, managers and thesel-employed in oundries. It may also be o assistance to employees, health andsaety representatives (HSRs) and consultants who work in the oundry industry.

Duties

Duties o employers

6. Section 21 o the OHS Act states that employers must, so ar as is reasonablypracticable, provide and maintain a working environment or their employees(including independent contractors and their employees) that is sae and

without risks to health.7. This means employers must eliminate any risks to health and saety, so ar as

is reasonably practicable. I it is not reasonably practicable to eliminate the risks,employers must reduce them so ar as is reasonably practicable.

8. Further, employers must, so ar as is reasonably practicable, monitor workplaceconditions and employees health, and provide employees with inormation onhealth and saety at the workplace. This should include the names o peoplethey can discuss their health and saety concerns with. Employers must alsokeep records relating to employees health and saety, and engage qualifedpeople to provide health and saety advice, so ar as is reasonably practicable(section 22).

9. In addition, the Regulations speciy that employers must:

ensurethatcontrolmeasuresareproperlyinstalled,usedandmaintained(regulation 2.1.1)

giveemployeessufcientinformation,instructionandtrainingaboutworkplace hazards and the need or proper use o and maintenance ocontrol measures (regulation 2.1.2)

provideinformationaboutthepurposeandnatureofhealthsurveillance,pay or health surveillance (regulation 2.1.3), and ensure that the employeeand any third party the employee authorises receives a copy o the resultso the health surveillance, and that the employers copy remains confdential(regulation 2.1.4).

10. Employers must also comply with additional duties prescribed in the

Regulations in relation to specifc hazards such as hazardous substances,lead, manual handling, plant noise and alls.

11. Employers need to give employees the inormation, instruction and trainingthey need to work saely and without risks to health, beore they start workin a oundry. Once work starts, employees need to be supervised. In particular:

employeesmustnotworkonanytaskuntiltheyhavebeengivensafetyand operational training and have been advised o emergency procedures

employersmustinstructemployeesinsafetyprocedures,thereasonsforthe procedures and the potential hazards o each task, in a language theemployee understands. I there are employees who speak English as asecond language, employers need to reer to WorkSaes Communicatingoccupational health and saety across languages compliance code

employersmustsupplypersonalprotectiveequipment(PPE)andinstructemployees on its proper ft, use and maintenance

Introduction



employersmustinstructemployeesinre-ghtingprocedures,theuseoffre-fghting equipment, and what to do in the event o a molten metal spill

employersmustinstructemployeesinsafemachineoperation,guardingrequirements and control measures

employeesneedtobeencouragedtoreportanyunsafeprocedures,equipment or work areas to their supervisor or manager

employeesneedtobesupervised,butifthenatureoftheworkrequiresanemployee to work in isolation, then all risks must be identifed and controlled,so ar as is reasonably practicable.

Duties o employees

12. Section 25 o the OHS Act places a duty on employees to take reasonablecare or their own health and saety and the health and saety o others whomay be aected by their work, and to cooperate with their employers eortsto make the workplace sae.

Controlling OHS hazards and risks

13. Good health and saety practice requires the elimination and control o hazardsand risks. This is best achieved by a proper consideration o the sources oharm and what can be done to prevent the harm rom occurring.

14. The control o OHS hazards and risks can be undertaken by a our-step process:

Step1Identifyhazards:knowwhathazardsarepresent.

Identiying hazards involves fnding all o the oreseeable hazards in theworkplace and understanding the possible harm that the hazards may cause.

Step2Assessrisks:understandthenatureofrisks,theharmthatcouldoccur and the likelihood.

Risk assessment is a process or developing knowledge and understandingabout hazards and risks so that sound decisions can be made about control.A ormal risk assessment is unnecessary i the knowledge and understandingalready exist. However, there will be many times when a risk assessment isthe best way o building knowledge and understanding.

Step3Controlhazardsandrisks:determineoptionsforeliminatingor reducing risk, select the best and implement it.

Duty holders are required to ensure health and saety by controlling risks.

Risks must be controlled by eliminating them so ar as is reasonablypracticable or, i this is not possible, reducing the risks that remainso ar as is reasonably practicable.

Step4Checkcontrols:reviewtheimplementedcontrolstoensuretheyare eective.

Controls that are put in place to protect health and saety need to bemonitored to ensure that they work as planned. This requires checkingthem and ensuring that processes are put in place to identiy and quicklyfx problems. Checking controls involves the same methods as in the initialhazard identifcation (Step 1), and creates the loop by which workplacehealth and saety measures are maintained. Control measures must bemaintained to ensure that they working eectively.

15. For more detailed guidance, reer to WorkSaes Controlling OHS hazardsand risks A handbook or workplaces.

Introduction



Introduction

Hierarchy of control

16. Employers must, so far as is reasonably practicable, identify tasks undertakenby employees that present risks to health and safety. This must be done inconsultation with employees and their HSRs. Employers must then eliminateor reduce those risks so far as is reasonably practicable.

Guidance on what reasonably practicable means can be found in the WorkSafePosition How WorkSafe applies the law in relation to reasonably practicable.

The Regulations prescribe that control measures be applied in a certain order(or hierarchy) for workplace hazards such as:

asbestos

connedspaces falls

hazardoussubstances

lead

manualhandling

noise

plant.

Refer to the Regulations for the prescribed hierarchy of controls for eachof these hazards.

The hierarchy of controls is the preferred and required order of controlmeasures for managing risks in foundries.

When deciding on the best way to control a risk, employers must start at thetop of the hierarchy of controls. First, investigate if the risk can be eliminated(eg by removing the hazard). If this is not reasonably practicable, then reducethe risk through substitution (eg by using safer substances or equipment). Ifthese methods are not reasonably practicable, use engineering or administrativecontrols to reduce the risk. Personal protective equipment (PPE) is the lastoption and the last line of defence. A combination of measures may be neededto adequately control the risk.

For more information about identifying hazards and controlling risks, refer to theWorkSafe Position How WorkSafe applies the law in relation to identifying andunderstanding hazards and risks.

Consultation

17. By law, so far as is reasonably practicable, employers must consult withHSRs and employees on a range of matters that directly affect (or are likelyto directly affect) their health and safety. In relation to OHS in foundries,examples of consultation would include:

consultationduringthehazardidenticationprocess

consultationontheselectionofsuitableriskcontrolstoreduceriskin foundries

consultationonanyproposedchangestosafeworkproceduresinfoundries.

18. For more information on the consultation provisions, see Appendix C and

WorkSafes Consultation on health and safety A handbook for workplaces.

Figure 1: Hierarchy of control.

EliminateRemove the hazard

Substitute

Something less hazardous

AdministrativeProcedures, training

or supervision

PPE

Gloves, glasses,boots, respirators

Engineer

Such as failsafe isolationor remote control devices



Molten metal explosions

Steam explosions

19. Steam explosions are caused by the introduction o moisture into molten metal.Sources o moisture include:

containersthatholdliquids(suchasdrinkcans,aerosolsormobilephone batteries)

heavilyoxidisedorrustedmaterials,orrustonthesurfaceoftoolsor equipment

damprefractoriesortools.

To control the risks, employers need to ensure that:

potentialsourcesofmoisturethatcouldcomeintocontactwithmoltenmetalare identifed, and steps are taken to prevent this. Ensure materials are reeo moisture on receipt and store in an appropriate dry location

furnacesandrefractoriesarepreheatedbeforeuse

allequipmentandtoolsarefreeofrustandarepreheatedbeforeuse(see page 25)

chargesaredryandfreefromanyentrappedmoisturebeforebeingaddedto molten metal (see page 27)

bottlesandcontainersthatholdliquidandsealedorpressurisedcansareprohibited (or i such items are required or maintenance or operational use,

their storage, use and disposal are strictly controlled by the employer).

Foundry hazardsand controls



Chemical explosions

20. Chemical explosions occur through the introduction o reactive chemicalsubstances to molten metal directly or as a contaminant in charge material.


personalbutanecigarettelightersarebannedinallmoltenmetalareas

paints,solventsandothercombustibleorammablematerialsarestoredin designated areas to avoid ignition and cross-contamination

storagesystemsareinplacetoensureproductsnotsuitableforusewithmolten metal are clearly labelled, secured against accidental use and stored

outside molten metal areas thelaststepbeforeaddinganythingtomoltenmetalisconrmingthat

it is the correct product and is sae or use in that particular melt.

Heat stress

21. Working in hot conditions is hazardous. Health eects range rom discomortor heat rash to heat exhaustion or heat stroke resulting in permanent damageor death. Heat stress can harm without the worker being aware o the degreeo eect until it is almost too late. It aects concentration, perception anddecision making, so heat stress is also dangerous in less obvious ways.

The risks o harm are controllable by a practical program, such as the oneoutlined on page 8.

22. Other actors besides urnace heat contribute to heat problems. Job actorsinclude strenuous and/or sustained work and inadequate recovery time.Seasonal actors include high air temperature and relative humidity or lowair movement. Excessive or inappropriate clothing or PPE and atigue arealso actors.

Foundry hazards and controls



23. Over time, employees who work in hot environments acclimatise or adapt to theheat. This reduces discomort, increases sweating eectiveness, reduces saltloss and returns recovery rate to normal. Acclimatisation takes time and is lostwhen employees are away rom the environment or example, i employeesgo on vacation. Employees who have been away or a week or more need tobe given time to reacclimatise. Acclimatisation only provides partial protection.While acclimatised workers are at less risk than unacclimatised, they arestill at risk.


unnecessaryheatandwatervapoursourcesareeliminated

radiantemissionsfromplantandotherhotsurfacesareshielded

spotcoolers,blowers,fansorairconditioningrelievehumidityandmovethe air

de-humidiersandotherhumidityreductionmethodsareused

ventilationsuchasuesdrawcoolerairin

tasksareautomatedwherereasonablypracticable

cleanfreshwaterissupplied

employeeshaveaccesstoarespiteareasuchasacoolroomorheatrefuge

apolicyandassociatedproceduresonheatstressaredeveloped

and employees are ully trained in the requirements. The policy needsto include:

an acclimatisation process

a buddy system where each looks ater the other

provision or requent short water breaks at regular intervals duringthe shit, (eg a cup o water (250ml) every 1520 minutes)

pacing o work to suit the conditions

scheduling o hot work in cooler parts o the day or isolating it by distancerom other workers

rotation o hot tasks between employees to minimise exposure time

employees are trained, educated and continuously monitored or

signs (symptoms) o excessive heat exposure and heat stroke contingency and treatment or aected employees

inadditiontoothercontrolmeasures,task-specicPPE(egwatercooledorheatreectiveclothingisprovided)(seepage35).




Burns

24. Burns are one o the major types o injuries in molten metal oundries andare generally caused by contact with hot suraces, radiation or moltenmetal splashing.


employeesnotdirectlyinvolvedincastingoperationsareseparatedfromthe casting area

automatedmachineryisusedsofarasisreasonablypracticable,toreduce risks associated with manual handling o casting moulds and

other equipment suitableprotectivebarrierssuchasscreensaroundthepouringstationare

provided to protect against the heat and splash when adequate saedistance cannot be provided

inadditiontoothercontrolmeasures,task-specicPPEisprovided(see page 35)

onlydryPPEisusedwhenworkingwithmoltenorhotmetal.

Light radiation

25. Eye disorders and skin burns may be caused by intense ultraviolet and inraredradiation rom molten metal in urnaces, particularly around pouring areas andin welding operations. Bystanders and passersby also need to be protected,preerably by exclusion.


shieldingandPPE,suchaslteredeyeprotection,areprovidedforallemployees who are likely to be exposed

allemployeesareadvisedoftherisksassociatedwithintenseultravioletand inrared radiation.

Hazardous substances

26. Hazardous substances such as lead, amines, ormaldehyde, toluene, phenol,ururyl alcohol and isocyanates are substances that can harm the health opeople exposed to them. They can be inhaled, swallowed or absorbed throughthe skin, and employees can suer immediate or long-term health eects.Exposure may cause irritation, chemical burns, cancer, birth deects or diseaseso certain organs such as the lungs, liver, kidneys and nervous system.

27. In addition, many airborne contaminants (eg gases, vapours, dusts and umes)that are hazardous substances can be produced rom oundry processes.




28. Gases such as acrolein, ammonia, carbon dioxide, chlorine, ormaldehyde,hydrogen chloride and sulphide, methane and nitrogen are oten storedas liquids under pressure. In the oundry, gases (eg sulphur dioxide, ozone,carbon monoxide) are oten by-products o oundry processes. Some gasessuch as carbon monoxide have no give-away odours and may not be detecteduntil their irritating eects such as respiratory difculty, coughing, asthmaand eye watering are detected.

29. Vapours such as benzene, dimethylamine, isocyanates, ormaldehyde andnaphthalene are the gaseous orm o substances that are liquid or solidat room temperature. They come rom solvents, paints, binders or catalyststhat evaporate during heating or spraying.

30. Dusts are generated rom solids and are dispersed by movements duringcleaning, loading or handling materials. Dusts have serious health implications.For example, wood dust causes alterations to the lining o the nasal cavity, skinrashes,inammation,asthmaandpossiblycancer.Metaldustscausesiderosis,tracheobronchitis, pneumonitis, beryllosis, systemic poisoning and nervoussystem damage. Also see pages 13 and 33.

31. Fumes are ormed when volatised solids (such as molten metals duringcharging and cleaning casts) condense in air. Fumes are also produced romthe binding agents, resins and catalysts used in sand moulds and cores andduring the melting and casting processes. Metal umes can cause cancer andrespiratory disorders.

32. Uncontrolled charging and melting processes can cause the excessive release

o metal umes or gases such as carbon monoxide, lead, zinc and other metaloxides. Accurate urnace temperature control is crucial in preventing excessivemelt uming.

33. Metal ume ever, an acute allergic condition, results rom exposure to beryllium,lithium, zinc, copper, aluminium, antimony, iron, nickel or magnesium. Symptomsareu-like:nausea,headache,fever,drythroat,coughingandmuscularpainsand start to appear our to 12 hours ater exposure ollowed by chills andsweats. Attacks last six to 24 hours, usually subsiding 24 to 48 hours aterremoval rom exposure.

34. Foundries should consult with Environment Protection Authority (EPA) Victoriaon the release o contaminants into the atmosphere (eg air, land, noise, water).

35. In addition to the industry-specifc controls shown on page 11, duty holders must

also comply with chapter our (Hazardous Substances and Materials) o theRegulations and be able to demonstrate the implementation o controls to atleast a standard detailed within the state o knowledge relevant to these hazards.





theuseofhazardoussubstancesiseliminatedwhereverpossible

hazardoussubstancesaresubstitutedwithnon-hazardoussubstancesorsubstances that are less hazardous or example, shot blasting o smallcastings instead o sand blasting (note that sand blasting is a prohibitedactivity)

workersareisolatedfromareaswherehazardoussubstancesareproduced(eg controlling a process rom a fltered air control room), and dust flteringor settling devices rom which air may escape are separated rom theworkplace (eg outside or in an enclosure vented to the open air)

engineeringcontrolsareusedtocontrolexposure(egcanopyhoodsnearurnaces and extractor hoods above urnaces capture umes and route themthrough an emission control system); ully enclosed extraction systems drawairborne contaminants away rom employees rather than through theirbreathing zone; melting operations use automatic thermocouple controlsystems to manage the melting process; down-draught tables and grillesare large enough to allow cleaning to be conducted within the boundarieso the down-draught

administrativecontrolsareputinplacetohelppreventorreduceexposure(eg restricting employee access to process areas); preventing eating,drinking and smoking in work areas; a clean as you go policy is introducedand cleaning methods involve wet and vacuum systems

ventilationsystemsareregularlyexaminedtoensuretheyaresafeandunctioning correctly and deects are repaired immediately

task-specicprotectiveequipmentandclothingiswornbyemployeesin the oundry (see page 35)

Monitoringisinplacetoensureexposurestandardsarenotexceeded(see Appendix D).

In addition you are required to ensure:

allsubstancesareincludedinahazardoussubstancesregisterthatincludestheir names and material saety data sheets (MSDS)

allsubstances(includingwastes)arestoredinlabelledcontainers

healthsurveillanceandbiologicalmonitoringisconductedwhererequired

recordsofmonitoringarekeptfor30years.




Lead

36. Lead is a poison that accumulates in the body. It enters the body by ingestionand inhalation. Symptoms o lead exposure include headaches, tiredness,irritability, constipation, nausea, stomach pains and anaemia. In excess it leadsto kidney, nerve and brain damage.

37. The Regulations require that employers provide job applicants and employeeswith inormation about the risks and toxic eects o lead exposure and theneed or and details o biological monitoring and medical tests. Further,employers must eliminate the risk so ar as is reasonably practicable to ensurethat employees do not exceed exposure standards and conduct atmosphericand biological monitoring where required.

38. In addition to the industry-specifc controls shown below, duty holders mustalso comply with Part 4.4 (Lead) o the Regulations, and the compliance codeor lead. Duty holders must also be able to demonstrate the implementationo controls to at least a standard detailed within the state o knowledgerelevant to these hazards.


workersareisolatedfromareaswhereleadfumesarebeingproduced

engineeringcontrolsareusedtocontrolexposure(egextractorhoodsaboveurnaces, dust extraction systems or bufng discing, grinding or cutting ocastings containing lead); lead melting operations use automatic

thermocouple control systems to manage the melting process administrativecontrolsareputinplacetohelppreventorreduceexposure

(eg rotating employees through a lead process to reduce exposure time);restricting employee access to process areas; preventing dry sweeping;work practices and equipment produce a minimum o residue

taskspecicprotectiveclothingandequipmentiswornbyemployeesintheoundry (see Personal protective equipment in the oundry page 35)

processesinvolvingleadareconnedtodesignatedareasandsignposted

leadprocessareasarekeptcleanandthatcleaningdoesnotincreasetherisk or others or spread contamination

eating,drinkingandsmokingareprohibitedinleadareas

provisionofchangingandwashingareasandthelaundry/disposalofleadcontaminated clothing

exposurestandardsarenotexceeded(seeAppendixD).

In addition, you are required to ensure that:

medicalexaminationsandbiologicalmonitoring(egregularbloodleadtesting)is conducted under the supervision o a registered medical practitioner

recordsofmonitoringarekeptfor30years.




Silica

39. Respirable crystalline silica is an occupational carcinogen. It causes silicosis(scarring o the lungs), a chronic disease that takes some time to develop.Its symptoms are shortness o breath, coughing and chest pain. These eectsare not reversible, and in the long term atal.

40. Silica dust is generated by a variety o processes such as mould and coremaking, cast cleaning, abrasive blasting, urnace maintenance, sand preparationand reclamation.

41. It is important that control measures are in place to ensure that theoccupational exposure limit o 0.1mg/m3 time weighted average (TWA) isnot exceeded. Sand and other materials containing more than one per cent

crystalline silica must not be used or abrasive blasting. This is a prohibitedactivity under the Regulations.

42. In addition to the industry-specifc controls shown below, duty holders must alsocomply with Part 4.1 (Hazardous Substances) o the Regulations and be able todemonstrate the implementation o controls to at least a standard detailedwithin the state o knowledge relevant to these hazards.


thereisapreferreduseofnon-silicaproductssuchaschromiteor olivine sand

wetorvacuummethodsorothermethodssuchastheadditionofbindersorsand delivery processes that reduce the amount o loose sand andeectively control potential generation o airborne particulate

mechanicalhandlingorpreparationlikelytogenerateoccupationallysignifcant concentrations o airborne dust and/or sand containing lessthan two per cent moisture or an alternative binding agent is not usedunless extractive exhaust ventilation is used to collect and ventilate dustaway rom people

enclosuresorchambers,sidedraughtordown-draughtexhaustventilationis introduced to control airborne contaminants rom most oundry processes

ventilationispositionedtodrawdustawayfromemployeesratherthanthrough their breathing zone

down-draughttablesandgrillesarelargeenoughtoallowcleaningtobeconducted within the boundaries o the down-draught

dustlteringorsettlingdevicesfromwhichairmayescapeareseparatedrom the workplace (outside or in an enclosure vented to the open air)

ventilationsystemsareregularlyexaminedtoensuretheyaresafeandunctioning correctly

defectiveand/orunsafeventilationsystemsarerepairedimmediately

airmonitoringisintroducedtoensurethattheexposurestandardisnot exceeded

acleanasyougopolicyisintroduced

task-specicprotectiveclothingandequipmentiswornbyemployeesin the oundry (see page 35).




Hazardous wastes

43. Legislative controls exist or the sae transport, storage and disposal ohazardous waste. Where no legislative controls apply, a sae means o transportand disposal (having regard to the nature o the hazard) needs to be employed(eg sealed, marked containers suitably protected rom possible damage andable to be handled saely).


hazardouswasteisclearlyidentiedandsealedinsuitablecontainers

containersaresecuredagainstdamage

task-specicprotectiveclothingiswornbyemployeesinthefoundry(see page 35).

Dangerous goods

44. Dangerous goods such as carbon dioxide, ormaldehyde, oxygen, sulphurdioxide and xylene are hazardous or a variety o reasons they may be highlyammable,explosive,corrosive,acutelytoxic,asphyxiantorhighlyreactiveaccording to class. They are readily identifable by class diamonds on the labels.

45. One o the biggest hazards in oundries is the potential or dangerous goodsto be incorrectly marked, mixed with common oundry salts and additives, and

placed into open crucibles or smelters containing molten metal. Major fres andexplosions have occurred at oundries causing deaths and substantial propertydamage. These incidents have involved the accidental mixing o class 5.1oxidizers such as ammonium or potassium nitrate or other oxidising salts intosmelters or crucibles containing molten metal or aluminium.

46. In addition to the industry-specifc controls shown below, duty holders must alsocomply with the regulations contained within the Dangerous Goods Act 1985and the Dangerous Goods (Storage and Handling) Regulations 2000 and beable to demonstrate the implementation o controls to at least a standarddetailed within the state o knowledge relevant to these hazards. For moreinormation, see Appendix D.





dangerousgoodsarelabelledcorrectly

useofdangerousgoodsisminimised

adangerousgoodsregistercontainingdetailsofalldangerousgoodsstoredand handled in the workplace is established and maintained. The registershould include material saety data sheets (MSDS) or each dangerousgood. The register must be accessible to all employees

MSDSarereviewedforproperties,effects,precautions,appearanceandsae handling techniques

employeeswhousedangerousgoodsareeducated,trainedandsupervised

ignitionsourcesarecontrolled

incompatiblechemicalsarestoredwellapartandwellawayfromsmelterprocess areas

dangerousgoodsarestoredawayfromhomes,meetingplacessuchasshops, schools and public buildings, other workplaces and propertyboundaries

placardsarelocatedonornearbulkstoresofdangerousgoodsandstorageand handling areas where required.

Slips, trips and alls47. Slips, trips and alls are a common hazard in most workplaces,

with consequences ranging rom mild (such as scrapes) to severe(such as ractures or atalities).

48. In addition to the industry-specifc controls shown below, duty holders mustalso comply with Part 3.3 (Prevention o Falls) o the Regulations and be ableto demonstrate the implementation o controls to at least a standard detailedwithin the state o knowledge relevant to these hazards.


triphazardssuchashoses,cordsandrubbishareeliminated

foundrylayoutisdesignedaroundworkow

oorsarelevel,rmanddurableanddonotaccumulatewater

oorsurfacematerialresistsdamagefromthefoundryprocess.Inareaswhere molten metal may spill, sand or reractory suraces that resist veryhigh temperatures are used

regularhousekeepingproceduresensurethatsandorotherprocessby-products do not build up

PPEtswellsothattrippingisnotlikely

Task-specicprotectiveclothingiswornbyemployeesinthefoundry(see page 35).




Manual handling

49. Manual handling tasks are those where orce is exerted by a person to lit,lower, push, pull, carry or otherwise move, hold or restrain any object. Theseoccur during pattern and core making, loading urnaces, moulding, ettling,dispatch, inspection and surace coating.

50. In addition to the industry-specifc controls shown below, duty holders mustalso comply with Part 3.1 (Manual Handling) o the Regulations and be ableto demonstrate the implementation o controls to at least a standard detailedwithin the state o knowledge relevant to these hazards.


hazardousmanualhandlingtasksareeliminatedwheneverpossible

theworklayoutmakesthetasklesshazardous(egcarryingitemslessdistance or using conveyors)

mechanicalaidsareusedwherepossible(egcranesorforklifts)

tools,equipmentandPPEaredesignedtominimisetheriskofanymanualhandling task that is created or changed

allstaffareadequatelytrained,educatedandsupervisedinmanualhandling saety.

Machinery and equipment (plant)

51. Machinery and equipment are used in pattern and core making as well ascasting and moulding. Plant such as cranes, hoists, orklits and conveyorsare also used as mechanical handling devices within oundries.

52. There are three kinds o hazards associated with machinery and equipment:

mechanicalhazardsduetomovingparts,ejectedobjectsandequipment(such as orklits) that may be operated in areas o pedestrian activity

non-mechanicalhazardssuchasairbornecontaminants,explosiveatmospheres, heat, radiation, chemicals, vibration, electricity and noise

accesshazards,includingconnedspaces,falls,andmanualhandling.

53. Employers need to carry out routine inspection and maintenance or allmachinery and equipment to ensure it remains in a sae working condition.The adverse environmental conditions ound in oundries (such as excessivevibration, machine lubricant contaminants, extreme heat and airbornecontaminants) all increase stress on fttings and components, potentiallyexposing machinery and equipment to premature ailure.

54. In addition to the industry-specifc controls shown below, duty holders must alsocomply with Part 3.5 (Plant) o the Regulations and be able to demonstrate theimplementation o controls to at least a standard detailed within the state oknowledge relevant to these hazards.




Mechanical hazards

55. Mechanical hazards include hard suraces coming together and scissoringaction. Risks include entanglement, crushing, severing, cutting andslips, trips and alls.


employeesareseparatedfrommachineryandequipmentbydistance(eg enclosures), barriers (eg guards) or time (eg when machine is disabled)

isolationproceduresarefollowedpriortoanymaintenanceorrepairworks

automaticsystemssuchastwo-handedoperation,presencesensorsor

ail-sae controls are in use machineryandequipmentisregularlyexaminedtoensureitissafeand

unctioning correctly and maintained to manuacturers specifcations

maintenance,repair,installation,serviceandcleaning(MRISC)activitiesare planned and saety supervision provided accordingly

purchasingpolicyfocusesonsafety.

56. For more inormation about mechanical hazards reer to WorkSaes Machineryand equipment saety An introduction.

Non-mechanical hazards

Noise

57. Noise levels in excess o 85 decibels (dB(A)) averaged over eight hours,or a C weighted peak hold sound pressure reading o 140 dB(C) can resultin hearing loss. Pattern and core making, moulding, knockout and cleaningoperations, ettling and some urnaces are among the equipment andprocesses that produce noise levels in excess o the acceptable standard.Regular exposure to excessive noise can damage the inner ear and causetinnitus leading to difculties in communications.

dB(A) levels of common foundry equipment

Mould vibrators L 85 114Inverter L 83 116

Arc/air gauging L 82 107

9-inch angle grinder L 97 110

Shot blasting L 86 101

Shake out L 84 95




58. In addition to the industry-specifc controls shown below, duty holders must alsocomply with Part 3.2 (Noise) o the Regulations and be able to demonstrate theimplementation o controls to at least a standard detailed within the state oknowledge relevant to these hazards.


currentriskcontrolsarecheckedtoensurethatthenoiseexposurestandardis not exceeded

currentplantismodiedorreplacedtoreducenoise

noisytaskstakeplaceinsoundproofenclosuresorbehindnoisebarriers quietrestareasareprovided

task-specichearingprotectioniswornbyemployeesinthefoundry(page 35).

59. Where hearing protection is required to be worn to control exposure to noisebelow the exposure standard, the employer is required to provide hearing tests(audiometric testing) every two years. The purpose o audiometric testing is todetermine whether employees have suered hearing loss due to exposure tonoise. I that is the case, the employer needs to review their controls.

Vibration

60. Whole body (180 Hz) vibration takes place during shake out, sand-slinging, onorklits, cranes and during pneumatic ramming operations. The adverse eectso whole body vibration include increased blood pressure and heart problems,nervous disorders, stomach problems as well as joint and spine injuries.

61. Hand-arm or segmental (8 Hz1 kHz) vibration occurs with hand-held grinders,chippers and other pneumatic tools. Adverse eects include narrowed arteriesin the hands and/or arms and damage to the nerve endings. Things thatchange vibration eects include the vibration requency, level o insulation,duration o exposure, resistance o the materials and orce o grip.


purchasingpolicyfocusesonsafety

processesareredesignedtominimisegrindingwherereasonablypracticable

oldtoolsarereplacedwithmodernvibrationreducedtoolsoraredampenedor insulated

employeestakefrequentbreaksandjobrotationisusedtoreduceexposure.

Electricity

62. Electric shock causes injury or death. A shock can be received through directcontact with live parts, through contact with a medium such as an unearthedtool or when it arcs across a gap. The risk is increased by excessive sweating,as wet skin is more conductive than dry skin.




63. Arcing, explosion or fre oten occurs as a result o high ault currents causingburns. Burning and arcing also produce a range o toxic gases, including ozone,cyanide and sulphuric acid. An additional hazard is low oxygen.


sourcesofelectricalriskareidentiedandeliminated

energysourcesareidentiedandde-energisedbeforemachinerymaintenance commences

testingandtaggingisscheduledandcarriedoutatleastannually

safetyswitchesareinstalledandtestedregularly

damagedcordsarereplaced

doubleadaptors,portablepowerleadsandadaptorsusedonapermanentbasis are prohibited

task-specicprotectiveclothingiswornbyemployeesinthefoundry(see page 35)

thermalimagingorinfraredscanningisusedtoidentifyelectricalproblems

accesstohigh-voltageareasisrestricted

apermitsystemisinuse

contractorsareappropriatelysupervised.

Machinery that may cause non-mechanical injury

64. Abrasive blasting and rumbling present hazards to employees rom airbornecontaminants and noise.


anexhaustventilationsystemisinoperationwhentheenclosureorchamberis occupied, including during cleaning, maintenance and repair work

exhaustventilationisdesignedandinstalledbyapersontrainedandexperienced in industrial ventilation, and includes provision or the routine

measurement o static pressure behind each hood aprocedureisinplacesothatremedialactionisinitiatedimmediately

i any aults or deects are identifed in the ventilation system

doorstotheenclosureorchamberareclosedwhileblastingorrumblingis in progress

windowsofimpact-resistantandshatterproofglassarettedtochambersto enable occupants to be clearly seen

enoughtimefortheevacuationofabrasivesanddustfromtheenclosureor chamber is allowed between fnishing blasting or rumbling and openingthe door (employees must not enter or leave while blasting is taking place)

controlsareoperablefrominsideandoutside.




65. Grinders present hazards to employees rom airborne contaminants and noise.


grindingareasareguardedtominimiseexposureofotheremployeestodust, particles and noise

hand-heldgrindersusedforprocessworksuchasdressingareconnedto as ew areas in the workplace as reasonably practicable

facilitiesfortheconnectionofxedmachinestodust-controlequipmentare incorporated in guard design

abrasivewheelsonpedestalbenchesareguardedtocontrolparticulates

toolrestsincorporateatonguepiece(enclosingthewheeledgebelowthe rest) to direct particles into the guard or dust control equipment.

Access hazards

66. Access hazards are oten complex, involving several risks at the same time,such as chemical dosing in confned spaces or working at height.

67. In addition to the industry-specifc controls shown below, duty holders mustalso comply with Parts 3.2 (Prevention o Falls) and 3.4 (Confned Spaces) othe Regulations and be able to demonstrate the implementation o controls toat least a standard detailed within the state o knowledge relevant to these

hazards. WorkSaes Prevention o alls in general construction and Connedspaces compliance codes provide urther guidance on these matters.


suitableplatforms,travelrestraintsandfall-arrestsystemsareusedwhenemployees are working at heights

employeesareeducated,trained,monitoredandsupervisedanduseapermit system or confned space entry.




Foundry layout

68. The layout o the work area needs to take into account the hazards associatedwith molten metal. Employers need to consider the ollowing issues:

Work ow


secondaryprocessesnotdirectlyrelatedtofurnacework,suchascleaningor rattling fnished products, do not take place near urnaces because theyrestrict movement around urnaces and put employees at additional risk.When it is necessary to conduct a process unrelated to urnace work near

a urnace, employers need to ensure employees are protected by barriersand protective clothing (see page 35)

quarantineproceduresareenforcedforentrytoanoperationalfoundry.The ollowing types o items have to be quarantined due to the hazards theypose when exposed to extreme heat, molten metal, radiation or or personalhygiene reasons:

mobile phones, portable radios or MP3 players such as iPods and otherbattery-operated devices

liquid uels such as cigarette lighters

ood and ood containers, especially open drink containers (oodand drink must not be consumed in an operational oundry and reshwater and meal acilities need to be well away rom the oundry

work environment) personal items such as jewellery and watches, especially i using

electromagnetic (induction) based urnaces

safetychecksaredevelopedforbothstandardworkandemergencyprocedures and they are tested. Emergency procedures, such as frst aidand fre drills, should take place at appropriate intervals consistent with therisks at site

employeesdonotworkundersuspendedobjectssuchascastings,mouldingboxes or ladles

itemsthatarenotbeingusedarestoredsafelyinnon-workingareas

drainsarecheckedregularlyforwater,rustedsteelorothermaterialsthatmay react with molten metal i a spill occurs. I possible, avoid having drainsin the oundry area.

Working withmolten metal



Working with molten metal

Facilities


therearesufcientclassDreextinguishersand/ordrysandavailableor fre fghting as sprinklers and water hoses are prohibited or fre fghtingin a casting acility

amenitiessuchastoilets,shelters,seating,diningrooms,changerooms,drinking water, washing acilities and personal storage are provided oremployees. They must be private and secure, adequate or the numbero employees and sufcient or the size o the workplace

In addition, duty holders must also be able to demonstrate theimplementation o controls to at least a standard detailed within the state oknowledge relevant to these hazards. See WorkSaes Workplace amenitiesand work environmentcompliance code or more inormation

safetyshowersandeyewashstationsareeasilyaccessibleonanunobstructed path at the same level and near the hazard. Ideally, they wouldbe accessible within 10 seconds, but oundry employers need to balancethe requirements o urnace and casting areas against wet areas. Thisbeing the case, saety showers and eyewash stations need to be locatednext to hazards where they do not pose a threat o explosion, and 15-20metres rom urnaces and casting areas. They need to be protected romextremes o temperature, well lit and use high-visibility signage. They needtoreleaseacontrolledowofushingliquid,thenozzlesandstoreduid

need to be protected rom contaminants and they must be tested regularly.

In addition, duty holders must also comply with WorkSaes First aid in theworkplace compliance code and be able to demonstrate the implementation ocontrols to at least a standard detailed within the state o knowledge relevantto these hazards.




Foundry buildings


workplatformsarehorizontalwherepossibleandaminimumof600mmwideto allow unimpeded movement o employees. The risk o objects alling romthe platorm needs to be prevented by a wall or in-flled handrail

theworkareaisclearofrubbishandhoses,andcordsshouldnotcrosstheoor

waterpipesorttingsthatareleakingordrippingarerepairedimmediately

aislesneedtobeopenandclear ammableanddangeroussubstancesarestoredsafelytoreduce

unnecessary exposure o employees to chemical and handling hazards.Cylinders containing gases need to be chained into position (outside urnaceareas), with clear and controlled access. They need to be protected romvehicle impact and other shocks and located away rom doorways andwindows. The area needs to be clear o rubbish and have sufcient lightingand appropriate signage

cablesandpipeworkarepositionedsotheyareprotectedfrommoltenmetal splashes

thereareasfewledgesandexposedbeamsaspossiblereverseconstruction or an internal skin wall will also protect services

theworkareaiswelllit

ahighroofallowsnaturalconvectionofgasesandfumes,alongwithventilation allowing adequate air exchange. However, atmosphericmonitoring must be carried out to determine i exposure standards areexceeded (see Appendix D)

theoorsurfaceissafe.Concretecanspallandexplodewhenincontactwithmoltenmetal(duetotrappedmoisture);refractorybrickisasaferoorsurace or the oundry area

openpits,deepmouldsandotherooropeningsaresecurelyfencedtoprevent employees alling in. The ence may consist o railings, chains andstanchions or a wall. It needs to be at least 9001100mm in height

wherepitsanddeepmouldsareinpermanentuse,theirinternalwallsneedto be lined with bricks, concrete or other similar material. This lining needsto:

retain the shape and sae condition o the pit

keep the pit or mould ree o moisture and seepage

pouringpitsneedtobelargeenoughtosafelyaccommodatealadle.Clearance o at least 300mm needs to be provided between all parts o,and attachments to, a ladle and the sides o the pit to allow unhinderedremoval o the ladle

whereanemployeeisrequiredtostandorworkoverornearaooropening,the edge o the opening needs to be covered by substantial grating topreventthemfallingintotheopening.Thegratingneedstobeushwiththesurroundingoororhaverampstopreventtheriskoftripping.




Furnaces

69. Furnaces pose a risk to employees through excessive heat and the potentialor mishap.


quickandeffectiveshut-offofservicestothefurnace,suchasgasor oil supplies (including hydraulic), is possible

build-upofexplosivegasorfuelispreventedbypurginggas-redandoil-fred urnaces

physicalcontactwithhotfurnacesorfurnacepartsispreventedbybarriers

or other means (eg doors that swing, pivot or slide in a way that directs hotsuraces away rom employees)

furnaceshaveareservoirtoreceiverun-outsofmoltenmetalincaseofreractory ailure. I the reservoir is not this large, containment plans needto be devised or controlling and containing metal spills. Reservoirs mustbe kept clean and dry.

Furnace tools

70. Rusty, cracked, worn and otherwise deective tools (eg ladles, bars and theirattachments) can cause bubbling, popping or explosions when introduced

to molten metal. Repairs pose additional hazards in the orm oairborne contaminants.

71. Modern graphite tools are especially porous and absorb more moisture thantraditional tools so they need preheating sufcient to eliminate the moisture.


toolsareinspectedfordefectsbeforebeingused

toolsarekeptfreeofrust

toolsarecompletelydrybeforeusetheycanbestorednearaheatsource(all tools need to be preheated beore use as they are likely to contain some

rust, and reractory coatings can also pick up moisture rom the atmosphere) toolsarefreeoftotallyenclosedcavities(allcavitiesshouldinclude

a vent hole that it is directed away rom the operator and positionedto prevent blockage)

repairandreliningofladlestakesplaceinadesignatedareawithdust extraction.




Raw material inspection

72. Material containing contaminants may trigger a violent reaction when addedto molten metal (see page 6). A thorough visual inspection o all materialsand packaging beore charging will ensure materials are clean, dry and reeo corrosion. Hollow objects such as tubes or pipes have the potential tocontain moisture. Add these items as the primary charge or return to thesupplier. Also see page 6.


anymaterialsthatwillbechargedintomoltenmetalareinspectedonreceipt

or contaminants such as: moisture

excessive grease and oil

corroded or oxidised metal

chemicals or unknown substances (any powdery substance needsto be treated as suspect, and residual ertiliser, nitrates and sulphatesare particularly dangerous)

contaminatedmaterialisquarantineduntilithasbeencleaned(incaseso heavy contamination or i the source o the contamination cannot beidentifed, the material needs to be returned to the supplier)

wherepossible,porouschargeorscrapthatmaycontainmoistureisadded

to the urnace as the primary charge.




Charging metal into the urnace

73. Charging the urnace is one o the most dangerous operations carried out inthe oundry, with incidents ranging rom minor injuries to atalities and seriousdamage to plant and equipment.

74. When using a reractory or crucible-type urnace, careully check the urnaceor cracks or excessive slag build-up. The reractory or crucible needs to bechanged or repaired i:

therearevisiblecracksontheinnersidewallsthatprovideriskoffailure

thereisasignicantskullonthesidewalls,or

metalisseenexitingthedrainport.

Various crucible types are used in oundry processes. It is best to consult withthe supplier or manuacturer about maintenance, repair and disposal requirements.

75. I metal is charged into a metal bath, it is important that the metal be dry beoreimmersion into the bath (see preheat charges below). Other important issues toconsider when adding metal to a metal bath are:

itmaybesafertoadddry,crackedorsuspectmetaltoafurnacewitha dry hearth

metalandalloyingadditionsareaddedgraduallytothemelt

whenachargeproducesexcessivebubblingorsmalleruptionswhenadded to a melt, the suspect batch o charges is quarantined and inspectedor contamination.


wherereasonablypracticable,furnacechargingisconductedbymechanicalmeans (i manual aids such as barrows and trolleys are used, they need tobe stable and easy or employees to control)

primaryPPEiswornbyemployees(seepage35).

Preheat charges

76. Water and other materials cause explosions when submerged below thesurace o molten metal (see page 6). For this reason, it is saest to assume

that all received metal is wet and to preheat it accordingly. The preheattemperature and duration will vary depending on the type o material, thedimensions and the quantity o charge.

77. Control is very important in preheating. Preheating could be done withheatfromthefurnacebypassingchargethroughhotzonesoruesforapredetermined time. Alternatively, hearth type urnaces in which the chargemelts through a hearth and joins a pool o molten metal overcomes thisproblem o moist charge reacting with molten metal. Materials heated aroundthe sides o an older style crucible urnace may not receive sufcient heatand are at risk o prematurely alling into the melt. However, materials stackedin ront o newer larger urnaces may receive sufcient heat.




78. Preheated charge can pick up moisture rom the atmosphere i there is a delayin using it, so whatever method is chosen, there needs to be a procedure ordetermining i the materials have been sufciently preheated beore addingto a melt.

79. I charging into an empty urnace or dry hearth, pre-heating may notbe required.


crackedorsuspectmetalisaddedtoafurnacewithadryhearth

sealedorclosedsectionsofscrapandchargethatmaycontainmoisture

or contaminant are opened

close-packedblocksandbundlesarebrokendowntofacilitateair circulation.

Alloying additions

80. All materials to be charged into molten metal need to be inspectedor contamination and cleaned beore charging in the same way asor metal (see page 26). Preheating using the same method as or metalis recommended or alloying additions, but there are some exceptionswhere preheating is not required or not recommended. In all cases, the alloysupplier needs to be consulted or correct practices or addition to metal.

81. Whereasubstanceistobeintroducedtomoltenmetal,suchasinuxing,de-gassing or inoculation processes, the substance needs to be clearlyidentifed to avoid the risk o mistaking it or something else. It needs tobe presented in a way that allows or its sae addition into the melt.


employeeswhoaddsubstancestomoltenmetalareawareofandfullytrained in the hazards o adding substances, and are properly supervisedby an employee who is aware o and ully trained in the hazards oadding substances.



Fluxing

82. Fluxes can be added to the melt or many reasons, including:

toreleasemetalfromthedrosstothemelt

tohelpremovedrossfromfurnacerefractorylinings

toremoveinclusions

toremovealkalimetalssuchassodium,lithiumandcalcium

topreventoxidationorhydrogenpick-up.

83. Manysalt-baseduxeseasilyabsorbmoisturefromtheatmosphereandthiscan result in violent explosions i added to a melt.


uxesarestoredinaccordancewiththemanufacturersinstructions

primaryPPEiswornbyemployees(arespiratormayalsoberequired),see page 35.

Dross

84. When skimming the dross, employees handle hot tools and are exposed tomolten metal and extreme radiant heat, so there is signifcant risk o burnsand molten metal splashing.


moistureandcontaminantsourcesareeliminated

forkliftsusedinskimmingoperationshaveprotectivescreensttedtothedrivers cabin

toolsanddrosspansarecleananddry,havearefractorycoatingandarepreheated beore use

primaryPPEiswornbyemployees(arespiratormayalsoberequired),see page 35.




Moving molten metal

85. Precautions need to be taken when moving molten metal around the oundry,regardless o how much metal is being moved.

86. Putting a lid on the transer vessel when practical is a good way o reducingspills and minimising heat loss.


atrafcmanagementplanensuresunnecessarypersonnelarenotin the vicinity o molten metal movements

wherereasonablypracticable,mechanicalaidsareusedtotransport,positionand pour molten metal; and mechanical ladles are ftted with devices toensure smooth positive control when tilting and pouring to preventaccidental tilting

whereladlesarecarriedbyhand,safemanualhandlingpracticessuchastwo-person lit, sae-grip points and other ergonomic considerations areobserved, and all single-hand carried ladles are ftted with a shield or guardthat protects the employee rom exposure to radiant heat

therouteusedtotransportmoltenmetalismarked,asshortaspossible,and clear o other people and objects

therearenogasorwaterlinesthatcouldcauseanexplosioni a spill occurred

theoorisclean,dryandabletowithstandmoltenmetaltemperatures

moltenmetalcarriershaverightofway

wheremoltenmetalistransportedbyhand,safepassagewaysandpouringaisles at least 800mm wide are provided

employeesintheareaarenotiedwhenmoltenmetalisbeingmoved(egbyashinglightsorhorns)

ladlesandtransfervesselsareinspectedregularlyforcracks

ladlesandtransfervesselsarepreheatedbeforeusetoremoveanymoistureabsorbed rom the atmosphere.




Moving molten metal with a orklit

87. Using a orklit to move crucibles or receptacles o molten metal is a commonpractice in many oundry operations.


forkliftshavesee-throughheat-resistantsplashguards(wind/blastshields)ftted between the drivers cabin and the load

gasline/couplingsongas-poweredforkliftsareshieldedwitha heat-resistant guard

wherepossible,electric-poweredforkliftsareusedratherthangasordiesel

when working with or near molten metal forkliftshavesufcientloadcapabilitiesandsufcientsafeliftingandreach

requirements

forkliftsuseappropriatelydesignedandratedliftingattachment

forkliftshavewell-designed,appropriatecabinaccessandergonomic seating

forkliftshavesolid(notpneumatic)tyres

forkliftshaverestraintstted,whichareusedbytheoperatoratalltimes

forkliftsundergoroutinemaintenanceasspeciedbythemanufactureror supplier, including tyres, tynes and liting attachments.

Slagging

88. Slagging hazards include heat, hot metal splashes and radiation.

89. I a slagging operation is perormed on a ladle that is transported by a crane,the operation could be conducted at a separate station where permanentcontrol measures are installed to protect employees rom the hazards othe slagging process.


employeesareprotectedbyshielding ventilationispositionedtodrawfumesawayfromemployeesratherthan

through their breathing zone





Tapping and pouring (casting)


employeesnotdirectlyinvolvedincastingarenotpresentduringthe operation

primaryPPEiswornbyemployees(respiratormayalsoberequired)in the oundry (see page 35).

Molten metal spills

Containing ow

90. When a metal spill occurs, employee saety must be the primary ocus. Boots,shovelsorhandtoolsshouldnotbeusedtostoptheow.Watermustnotbeused on metal spills.


abucketofclean,drysandisstorednearthefurnace,whichcanbeusedtostoptheowofspills(ifthiscanbedonesafely)


Cleaning up metal spills

91. Beore any action is taken to clean up metal spills, the risks o the situationneed to be ully assessed. I it is sae to do so, it may be possible to break themetal into sections beore it ully solidifes, using a urnace tool. Primary PPEmust be worn when doing this (see page 35).

92. I it is unsae to intervene, the spill will have to be cleaned when the metal hassolidifed by liting it rom the ground with hand tools. For metal that is moredifcult to remove, an oxygen lance may be required. An oxygen lance is anextremely dangerous piece o equipment and extra precautions (such asadditional PPE and ull training in its use) are required. It is also importanttomakesurethesurroundingareaisfreeofanystandingwaterorammable

materials because molten metal can spray o the lance and onto these items,causing an eruption.


ariskassessmentisdonetodeterminethesafestwaytoproceed

surroundingareasarefreeofwaterandothercontaminants





Housekeeping

Ater casting

93. When casting is complete, a number o tasks need to be done to ensure theoundry is sae or the next casting process.


thefurnaceisemptied,cleanedandinspected

thetoolsarecleanedandrecoated.

Cleaning dusts

94. Compressed air must not be used or cleaning unless the task cannot be doneany other way. I compressed air is used, control measures such as reducing airpressure and providing protective equipment need to be in place. Compressedair must never be used to clean clothing or the body. Also see page 9.


workpracticesandequipmentproduceaminimumofresidue

plant,xturesandstructuresarecleanedregularly

sandorearthoorsinfoundriesareappropriatelymanagedtopreventdustrising.Ifthisinvolvesusingmoisture,thesandorearthoorsshouldnotbewet enough to trigger a steam explosion

dustextractionisbyexhaustventilation

theyusetechnologiessuchasfoggingtoreducedust.However,consideration needs to be given to the impact on the environment (eghumidity and heat stress and other risks associated with increases inatmospheric moisture)

wetcleaningtakesplacewhereitpresentsnoadditionalrisk

employeesusevacuumcleanerswithhighefciencyparticulateair(HEPA)lters

cleaningisaregularpartofpreventativemaintenanceprograms.

Equipment storage


equipmentsuchasmouldingboxes,patternsandequipmentthatarestacked are stable and ree rom dangerous projections

furnacetoolsarestoredsotheyarecleananddryandofftheoorinsuitable racks at a height that is easily accessible.





Material storage


materialsareinspectedandthenstoredinclearlylabelledcontainersin permanent specifcally designated areas that are clean and dry

metalchargesandmaterialsthatwillcomeintocontactwithmoltenmetalare kept undercover to prevent the absorption o moisture

containersincludeholesorotherdesignfeaturestofacilitatedrainageand prevent the accumulation o contaminants such as oil or water

processmaterialsandsubstancesarestoredinseparatecontainers,process

residues are stored saely and in a manageable orm and materials that arenot used in the process are stored separately rom the process materials

materialsnotsuitedforuseinmoltenmetalarenotstoredwiththerawmaterials or in the oundry area

aregisterdescribinghazardsandsymptomsofexposuretomaterialsand substances ound in the workplace is created and maintained.



95. Employers must ensure that PPE is supplied to all employees, including labour

hire sta and contractors. It must be replaced when it is no longer capable oproviding the necessary protection (eg it is damaged or worn).

96. For oundry purposes, compliance is demonstrated by employers supplyingthe two categories o PPE to employees in conjunction with a program ormanaging PPE:

Primary protective clothingisusedforspecichazardoustasksthenremoved. It provides protection rom hazards such as metal splash andradiantheat.Thegarmentsneedtobemadefrominherentlyre-retardantabrics to ensure their protective properties are intact as long as the garmentis intact. They need to be comortable to wear and breathable in veryextreme work conditions. Leather options oer some durability and protectivebenetsbutcancompromisecomfortandaddtoheatstressincertain

situations (see table on page 36). Secondary protective clothingisall-day/everydayclothing.Theclothingneedstobere-retardantandthechoiceofinherentortreatedcantakecomort and cost into account, but these garments are the last deenceor the body i primary protection ails. A cotton abric is the minimumrequirement, but specially treated cotton or wool abric is recommended(see table on page 36).

97. Therearetwoclassesofre-retardantclothing:

Treated garments require additional attention to preserve their protectiveproperties such as particular cleaning or protection rom some kinds ochemicalsorexcessiveheat.Manyhavelimitedlifespansorefcacythatdeclines over time.

Inherent/permanent garments do not require special care to preserve theirprotection. Their protection lasts as long as the garment does.

98. Garmentsaredesignedtowithstandreandshedmoltenmetalquicklyandeffectively.Badlyttedgarmentscancreatefoldsthatcatchandholdthemetal,making them less protective.

99. Style is also important or example pockets and faps create catch points,metalbuttonsheatupfromradiantheatandre-retardanttapecanstoptheabric breathing and cause sweat/burn marks i not placed well on a garment.High-visibilitycolouroptionscanassistwithsitevisibility.

Figure 2: Cotton shirt ater moltenmetal pour

In areas where the molten metal wastrapped or rested against the material such as pockets, button holes, insidegloves or at the waistband o pants it burnt through rapidly and in someinstances caught alight. The burnt edgessmouldered until physically stamped out.

Figure 3: Wool viscose shirt (one exampleofaame-resistantfabric)aftermolten

metal pourWool viscose does not burn through asquickly, giving the wearer time to removethe clothing beore urther injury occursand providing increased protection rommolten metal splashes.

Personal protectiveequipmentin the foundry



The inormation given below is a guide only. Dierent metals and oundry processes have dierent PPE requirements.See Appendix F or selection o appropriate PPE.

Primary and secondary PPE

Primary PPEfor molten metal work(in addition to secondary PPE)

Secondary PPEfor general foundry work

HEADUse helmets where there is potential or items to all rom height or where work takes place above head height(eg on a mezzanine). Industrial saety helmets should be considered. Where tasks result in dust or particulates,

a head covering should be considered.

EARSThe actors that need to be taken into account when selecting hearing protectors need to include compliance withAS 1270, level o noise, the wearer (eg personal characteristics, comort), communication requirements, and compatibilitywith the job/workplace. Guidance on hearing protectors is provided in AS/NZS 1269.3.

EYES AND FACEFace shields with neck protection.

EYES AND FACEIndustrial saety glasses with side shields are the minimum.

RESPIRATORYRespiratory protective devices (RPD) used need to comply with AS/NZS 1716. The type o respirator selected needs

to take into account the operator (ie acial hair, physiological and psychological actors), the task (ie how the job is done,duration, requency) and the substance (ie type o contaminant, concentration). The standard AS/NZS 1715 providesguidance on the selection, use and maintenance o respiratory protective devices. Guidance can also be obtained romsuppliers o respiratory protective equipment.

Personal protective equipment in the foundry



Primary and secondary PPE

Primary PPEfor molten metal work(in addition to secondary PPE)

Secondary PPEfor general foundry work

TRUNK AND ARMSA jacket o leather or other suitably resistant materialmust be worn outside all other clothing. It must be ree oeatures such as cus and pockets that may trap moltenmetal. It must be worn properly and astened at all times.

TRUNK AND ARMSLong-sleevedshirtmadefromame-resistantfabricsuch as wool, heavy cotton drill, Firewear, TuWeld andIndura,orfabricswithame-retardantcoatingssuchasFlameShield, aramid or Trevira CS. Employers must provide

refective clothing where there is a risk radiation andheat may aect health. Garments need to asten at theneck and wrists to prevent molten metal splashes, dust,chemicals and other substances rom entering throughthe collar and cus.

HANDSHeat-resistantKevlarorheavyleathergauntletsthatcoverthe lower part o arm.

HANDSGloves selected need to take into account the hazard(eg burns, abrasion, chemicals, cuts), the work environmentandthewearer(egt,comfort,dexterity).Guidanceonthe selection, use and maintenance o protective glovesis provided in AS/NZS 2161.1.

LEGS

Where risk o molten metal spills or splashes exists,trousers o leather or other suitably resistant materialsmust be worn. The trousers need to cover the top othe ootwear and be ree o eatures such as cusand pockets that may trap molten metal.

LEGS

Heat-resistanttrousers.

FEETEmployeesmustwearsafetyfootwearatalltimesintheworkplaceunlessalegallyqualiedmedicalpractitionercertiesthat wearing saety ootwear would injure the wearer. In such cases, the reason or such an opinion must be given andthe most appropriate alternative protective equipment sought.




Storage and care of protective equipment

100. For oundry purposes, compliance is demonstrated by employers ensuring that:

allprotectiveequipmentandclothingprovidedismaintainedinsoundcondition, tested routinely and capable o perorming the protective unctionsor which it was provided

employeesaretrainedintheneedfor,effectiveuseandcareof,andmeansoftestingthetofprotectiveequipment(whentrainedemployeesmustcooperate in the care and maintenance o the equipment)

equipmentandclothingisonlywornbytheemployeetowhomitwasissued,and is marked with the name o that employee

cleanstorageisprovidedforallprotectiveequipmentandclothing

maintenanceofclothingandequipmentisconductedwhenrequiredandinthe manner prescribed by the manuacturer or supplier.Figure 4: Primary protective clothing

(Molten metal work)

Helmet with face shieldand neck protection wornwith safety glasses

Casting jacket wornover secondaryprotective clothing

Heat resistant Kevlaror heavy leather gauntlets

Safety boots

Figure 5: Secondary protective clothing(General oundry work)

Safety glasses

Long-sleeved shirt

Gloves

Long pants

Safety boots




Appendices

Appendix AThe compliance ramework

Appendix B

Defnitions

Appendix C

Consultation

Appendix D

Hazardous substances: exposure standards, atmospheric monitoringand health surveillance

Appendix E

Dangerous goods in oundry operations

Appendix F

Eective PPE program

Appendix G

Further inormation



A handbookfor workplaces

Working safelywith bridge andgantry cranes

June2008EditionNo.1

Occupational Health andSafety Act 2004

Act No. 107/2004

The Occupational Health and Safety Act 2004 (the OHS Act)sets out the key principles, duties and rights in relation tooccupational health and safety (OHS).

Occupational Health andSafety Regulations 2007

Statutory Rule No. 54/2007

The Occupational Health and Safety Regulations 2007 (theRegulations) specify the way in which a duty imposed by the OHSAct must be performed, or prescribe procedural or administrativematterstosupporttheOHSAct(egrequiringlicencesforspecicactivities, the keeping of records or giving notice).

Compliance codes provide practical guidance to duty holders.

If a person complies with a provision of a compliance code, theyare deemed to comply with the OHS Act or Regulation dutycovered by the code provision. However, compliance codes are notmandatory, and a duty holder may choose to use some other way toachieve compliance.

WorkSafe Positions are guidelines made under section 12of the OHS Act that state how WorkSafe will apply The OHSAct or Regulations or exercise discretion under a provision of

the OHS Act or Regulations. WorkSafe Positions are intendedto provide certainty to duty holders and other affected parties.

Non-statutory guidance includes information published byWorkSafe aimed at building peoples knowledge and awarenessof OHS issues, risks to health and safety, and the disciplines andtechniques that can be applied to manage and control risks.Non-statutoryguidanceisnotmandatory,nordoesitprovideanydeemed to comply outcomes for duty holders. This guidance does,

however, form part of the state of knowledge about OHS.

Appendix A The compliance framework

Appendices



Appendix B Defnitions

Charge

Material to be added to the urnace,such as pre-cast ingots, metal scrap,virgin metal material and variousmeltingagents,suchasuxes.

Dangerous goods

Specifc substances listed in Appendix 2o the Australian Code or Transport oDangerous Goods by Road and Rail or

satisy the criteria o columns 2, 7 or9 in the appendix; or are determined tobe dangerous goods under paragraph1.18 o the Code or satisy the UNdangerous goods tests and criteria ordangerous goods (as defned by theDangerous Goods Act 1985).

Dry hearth

One that does not contain liquid metal.

Ferrous foundry

A oundry that produces castingso iron or steel.

Hazardous substance

A substance listed on the AustralianSaety and Compensation CouncilsHazardous Substances InormationSystem, or which meets the criteriain the Approved Criteria or ClassiyingHazardous Substances (as defned bythe Regulations). The substance canbe solid, liquid or gas, and when usedin the workplace is oten in the orm

o gases, vapours, umes and dusts.

Manual handling

Any activity requiring the use oorce exerted by a person to lit,lower, push, pull, carry or otherwisemove, hold or restrain any object(as defned by the Regulations).

Material safety data sheet (MSDS)

A document that provides the inormationneeded to ensure the sae handling ohazardous substances, prepared by themanuacturer or importing supplier (asdefned by the Regulations). Inormationon the properties o the substance, itstoxicity, reactivity and precautions orsae use are included in an MSDS.

Non-ferrous foundryProduce castings based on copper,aluminium, lead, zinc, nickel, magnesiumand other non-errous metals.

Personal protective equipment (PPE)

Equipment or clothing used to providepersonal protection such as gloves,gauntlets, saety glasses, helmet, goggles,earmus, saety shoes, respirators orall arrest systems.

Plant

Any machinery, equipment, appliance,implement and tool, any component oany o those things, and anything ftted,connected or related to any o thosethings (as defned by the OHS Act).

Short-term exposure limit (STEL)

A 15-minute time weighted average(TWA) exposure that should not beexceeded at any time during a workingday even i the eight-hour TWA averageis within the TWA exposure standard.

Exposures at the STEL should not belonger than 15 minutes and should notbe repeated more than our times perday. There should be at least 60 minutesbetween successive exposures at theSTEL (as defned by the Australian Saetyand Compensation Council).

Time weighted average (TWA)

The average airborne concentrationo a particular substance whencalculated over a normal eight-hourworking day, or a fve-day working week(as defned by the Australian Saety andCompensation Council).

Appendices



Appendix C Consultation

By law, employers must consult with employees on a range o matters thatdirectly aect (or are likely to directly aect) their health and saety, so ar asis reasonably practicable.

Consultation must involve sharing inormation with employees, giving the employeesa reasonable opportunity to express their views and taking those views into account.

Where employees are represented by HSRs, these representatives must be involvedin the consultation, so ar as reasonably practicable.

The law sets out specifc requirements on how HSRs are to be involved inconsultation. These are as ollows:

ProvideHSRswithalltheinformationaboutthematterthattheemployerprovides,or intends to provide, to employees. I it is reasonably practicable,the inormation must be provided to the HSRs a reasonable time beoreit is provided to employees.

InvitetheHSRstomeetwiththeemployertoconsultonthematterormeetwith the HSRs at their request.

GivetheHSRsareasonableopportunitytoexpresstheirviewsonthematterand take those views into account.

The employer must include independent contractors and their employees in theconsultation, so ar as is reasonably practicable, i the employer has, or should have,control o a relevant matter that aects their health and saety.

Consultation is required when: identifyingorassessinghazardsorrisks

makingdecisionsonhowtocontrolrisks

makingdecisionsabouttheadequacyoffacilitiesforemployeewelfare(such as dining acilities, change rooms, toilets or frst aid)

makingdecisionsaboutproceduresto:

resolve health and saety issues

consult with employees on health and saety

monitor employee health and workplace conditions

provide inormation and training

determiningthemembershipofanyhealthandsafetycommitteeintheworkplace

proposingchangesthatmayaffectemployeehealthandsafety,suchaschangesto:

the workplace

plant, substances or other things used in the workplace

the work perormed at the workplace

doinganyotherthingprescribedbytheRegulations.

In practice, this means that when planning to implement measures identifed in thiscompliance code, or when making decisions to implement alternative measures tothose specifed in this compliance code, consultation must take place.

Appendices



Appendix D Hazardous substances:exposure standards, atmospheric monitoringand health surveillance

Exposure standards

Employers are required to ensure that no employee is exposed to an airborne levelo a hazardous substance that is above the national exposure standard as set outby the Australian Saety and Compensation Council (ASCC).

Exposure standards represent airborne concentrations o substances in a personsbreathing zone, which according to current knowledge, should not impair employeeshealth or cause them undue discomort. Exposure standards do not represent a

fne line between sae and unsae. Thereore exposure to airborne contaminantsneeds to be reduced so ar as reasonably practicable and not just below theexposure standard.

The latest inormation on exposure standards or hazardous substances should beperiodically reerred to and can be ound in the HSIS database on the ASCC websitehsis.ascc.gov.au.

Atmospheric monitoring

Atmospheric monitoring is required where there is an exposure standard or theairborne contaminant and there is uncertainty, based on reasonable grounds, asto whether the exposure standard is or may be exceeded. This means that i it isclear or obvious that exposure is not signifcant and thereore not likely to exceed

the exposure standard, monitoring is not required. Similarly, atmospheric monitoringis not required i it is obvious that exposure is excessive. In this case, the employerneeds to eliminate or control the risk so ar as is reasonably practicable.

Personal monitoring in an employees breathing zone is considered the mostappropriate monitoring technique.

Examples o situations where there may be uncertainty or where atmosphericmonitoring may be needed include:

theprocessorhazardoussubstanceisnewandthereisuncertaintyasto the level o exposure or risk

theprocessiscarriedoutsporadicallyortheexposurevariesinlevel,frequencyor duration

itisnotclearwhetherneworexistingriskcontrolsareeffective(egventilation) therisktohealthislargelycontrolledthroughtheuseofrespiratoryprotection

therisktohealthislargelymanagedthroughadministrativecontrols(iesafework practices or systems o work such as job rotation)

thereisevidencethattheriskcontrolshavedeterioratedasaresultofpoor maintenance

processmodicationsorchangesinworkpracticeshaveoccurredthatmayaect exposure.

Atmospheric monitoring only tests or potential exposure through inhalation andmay not always represent an employees actual total e

foundries- worksafe no. 1 (2008)

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