Foundry Safety Manual

Foundry Safety Programs

The safety programs needed by a foundry depend on its metals, processes, and equipment. A comprehensive manual may include programs covering:

• Molten Metal Safety
• Furnace Safety
• Silica Exposure Control
• Respiratory Protection
• Personal Protective Equipment
• Heat Stress Prevention
• Machine Guarding
• Lockout/Tagout
• Crane and Hoist Safety
• Rigging and Material Handling
• Conveyor Safety
• Hearing Conservation
• Hazard Communication
• Welding, Cutting and Hot Work
• Forklift and Powered Industrial Truck Safety
• Electrical Safety
• Confined Space Entry
• Job Safety Analysis
• Emergency Action Plan
• Fire Prevention

Additional programs should be included when specific metals, chemicals, processes, or equipment create additional hazards.

Foundry Hazard Assessment

Foundry operations should be evaluated to identify the hazards associated with each process.

The assessment should consider:

• Molten metal
• Extreme heat
• Metal splash
• Steam explosions
• Silica
• Metal fumes
• Metal dust
• Carbon monoxide
• Mold and core chemicals
• Combustion products
• Noise
• Machinery
• Hazardous energy
• Material handling
• Cranes and hoists
• Fire and explosion
• Ergonomic hazards

Changes in metals, alloys, binders, equipment, or production methods should be evaluated for new hazards.

Molten Metal Safety

Molten metal can cause catastrophic burns, fires, explosions, and equipment damage.

Employees working around molten metal should understand the hazards associated with:

• Furnaces
• Ladles
• Crucibles
• Transfer
• Pouring
• Charging
• Slag and dross
• Moisture
• Tools
• Molds
• Spills

Access to molten-metal areas should be limited to employees whose work requires them to be there.

Molten Metal and Water

Water contacting molten metal can rapidly turn to steam and violently eject molten material.

Foundry procedures should prevent water and uncontrolled moisture from contacting molten metal.

Employees should inspect:

• Scrap
• Charge materials
• Ladles
• Tools
• Molds
• Furnace areas
• Transfer equipment

Materials suspected of containing trapped water, ice, snow, or excessive moisture should not be introduced into molten metal until they have been handled according to an established safe procedure.

Wet Scrap and Charge Materials

Scrap and other furnace-charge materials should be inspected before charging.

Potential hazards include:

• Water
• Ice
• Snow
• Closed containers
• Pressurized components
• Unknown materials
• Oil
• Contaminants

Charge materials should be suitable for the furnace and process.

Employees should not assume scrap is safe simply because it appears dry externally.

Closed Containers in Scrap

Closed or partially closed containers can trap moisture, liquids, gases, or pressure.

Scrap should be inspected to identify potentially hazardous containers or components before charging.

Examples may include:

• Tanks
• Cylinders
• Tubing
• Pipe
• Sealed assemblies
• Hollow components

Suspect materials should be handled according to established procedures.

Furnace Safety

Foundry furnaces may include:

• Cupolas
• Electric arc furnaces
• Induction furnaces
• Crucible furnaces
• Reverberatory furnaces
• Other melting equipment

Employees should be trained for the specific furnace they operate.

Procedures should address:

• Startup
• Charging
• Melting
• Temperature
• Tapping
• Shutdown
• Maintenance
• Emergency conditions

Furnace safety systems should not be bypassed.

Furnace Inspection

Furnaces should be inspected according to manufacturer recommendations and facility procedures.

Inspections may include:

• Refractory condition
• Cooling systems
• Electrical systems
• Hydraulic systems
• Fuel systems
• Controls
• Guards
• Emergency systems
• Structural components

Conditions that could affect safe operation should be corrected.

Furnace Charging

Charging operations should be planned to reduce molten-metal splash and other hazards.

Employees should:

• Inspect charge material.
• Use appropriate charging equipment.
• Maintain safe positioning.
• Avoid uncontrolled dropping of material.
• Keep unnecessary employees clear.
• Wear required PPE.

Large or irregular charge materials should be handled carefully to prevent bridging or sudden movement.

Bridging in Furnaces

Charge material can occasionally bridge above molten metal.

A bridge can create hazardous conditions if molten metal or superheated material becomes trapped beneath it.

Employees should not use improvised methods to break a bridge.

Bridge removal should follow established procedures appropriate to the furnace and process.

Furnace Tapping

Employees involved in furnace tapping should maintain safe positions and clear escape routes.

Procedures should address:

• Ladle positioning
• Communication
• Molten-metal flow
• PPE
• Floor conditions
• Emergency response

Employees not necessary to the operation should remain outside the tapping area.

Ladle Safety

Ladles used to transport molten metal should be suitable for the metal, temperature, quantity, and handling method.

Ladles should be inspected for:

• Refractory condition
• Cracks
• Structural damage
• Trunnions
• Hooks
• Gear mechanisms
• Handles
• Safety devices

Damaged ladles should be removed from service.

Ladle Preheating and Drying

Ladles and tools that contact molten metal should be appropriately dry and conditioned before use.

Preheating procedures should be established when required by the process.

Employees should not introduce wet equipment into molten metal.

Ladle Transport

Molten metal may be transported by:

• Overhead cranes
• Monorails
• Forklifts
• Ladle carriers
• Manual equipment
• Specialized transfer systems

Travel routes should be established and maintained.

Employees should remain clear of molten-metal transfer paths whenever possible.

Overhead Molten-Metal Movement

When molten metal is moved overhead, unnecessary personnel should remain clear of the load path.

Operators should maintain control of the ladle and avoid sudden movement.

Travel routes should be kept free of unnecessary obstructions.

Communication should be established when visibility is limited.

Pouring Operations

Pouring molten metal into molds can expose employees to splash, heat, fumes, gases, and mold failure.

Before pouring:

• Verify mold condition.
• Maintain clear access.
• Confirm ladle condition.
• Keep unnecessary employees clear.
• Inspect the pouring area.
• Use required PPE.

Pouring should be controlled to prevent unnecessary turbulence and splash.

Mold Condition Before Pouring

Molds should be prepared according to established foundry procedures.

Potential hazards include:

• Excessive moisture
• Damaged molds
• Improperly secured molds
• Obstructed vents
• Incorrect assembly
• Contamination

Employees should report conditions that could cause mold failure or violent reaction during pouring.

Molten-Metal Splash

Employees exposed to molten-metal splash should wear PPE selected for the specific metal and operation.

Potential controls may include:

• Face protection
• Eye protection
• Heat-resistant clothing
• Gloves
• Protective footwear
• Leg and foot protection
• Screens or barriers

PPE should be designed and worn so molten metal is less likely to become trapped against the body.

Molten-Metal Spill Response

Foundries should establish procedures for uncontrolled molten-metal releases.

Employees should know:

• Alarm procedures
• Evacuation routes
• Restricted areas
• Emergency shutdown procedures
• Who is authorized to respond

Employees should not attempt to control a major molten-metal spill unless specifically trained and equipped.

Foundry Floor Conditions

Molten-metal areas require particular attention to floor conditions.

Employees should report:

• Standing water
• Wet areas
• Oil
• Debris
• Damaged flooring
• Obstructions
• Uneven surfaces

Water should not be allowed to accumulate where molten metal could contact it.

Molding Operations

Foundries may use:

• Green sand
• Resin-bonded sand
• Shell molds
• Permanent molds
• Investment molds
• Other molding systems

Hazards depend on the materials and equipment involved.

Procedures should address:

• Dust
• Chemicals
• Machinery
• Material handling
• Ergonomics
• Ventilation

Foundry Sand Safety

Sand used for molds and cores may contain crystalline silica.

Employees may be exposed during:

• Sand handling
• Mixing
• Molding
• Coremaking
• Shakeout
• Sand reclamation
• Casting cleaning
• Housekeeping

Dust generation should be minimized.

Silica Exposure

Respirable crystalline silica can be generated during many foundry processes involving sand molds and cores.

Potential exposure areas include:

• Molding
• Coremaking
• Shakeout
• Sand reclamation
• Casting cleaning
• Chipping
• Grinding
• Abrasive blasting
• Housekeeping

Employee exposures should be evaluated and controlled according to applicable requirements.

Silica Engineering Controls

Engineering controls should be used where appropriate to reduce respirable silica exposure.

Controls may include:

• Local exhaust ventilation
• Enclosures
• Downdraft booths
• Dust collection
• Automated processes
• Wet methods
• Isolation

Ventilation and dust-control systems should be inspected and maintained.

Foundry Housekeeping and Silica

Cleaning methods should minimize airborne silica and metal dust.

Appropriate methods may include:

• HEPA-filtered vacuuming
• Wet cleaning
• Other controlled methods

Dry sweeping or compressed-air cleaning should be restricted where it can create hazardous airborne exposure and safer methods are feasible or required.

Coremaking

Coremaking can involve sand, binders, resins, catalysts, gases, and heated equipment.

Employees may be exposed to:

• Silica
• Chemical vapors
• Dust
• Heat
• Moving machinery
• Ergonomic hazards

Coremaking processes should be evaluated for both chemical and physical hazards.

Mold and Core Binders

Mold and core systems may use chemical binders capable of producing hazardous vapors or decomposition products.

The hazards depend on the chemicals and process.

The facility should evaluate:

• Safety Data Sheets
• Process temperatures
• Ventilation
• Employee exposure
• Storage
• Mixing
• Spill response
• PPE

Employees should receive training concerning the binders and catalysts used in their work areas.

Mold and Core Decomposition Products

When molten metal contacts molds and cores, high temperatures can generate gases, vapors, and decomposition products.

Ventilation should be designed and maintained to control process emissions.

Employees should report:

• Unusual odors
• Smoke
• Visible emissions
• Ventilation failures
• Irritation symptoms

Exposure evaluation should consider the specific molding and core materials used.

Shakeout Operations

Shakeout separates castings from molds and can generate significant amounts of dust, noise, vibration, heat, and flying material.

Employees should be protected from:

• Silica dust
• Hot castings
• Moving equipment
• Noise
• Falling material
• Pinch points

Shakeout systems should be appropriately enclosed or ventilated where feasible.

Sand Reclamation

Sand-reclamation systems may include conveyors, screens, crushers, elevators, separators, mixers, and other machinery.

Hazards may include:

• Silica
• Dust
• Moving machinery
• Noise
• Hot material
• Hazardous energy

Employees should not enter or reach into operating reclamation equipment.

Casting Cooling

Fresh castings may remain hot for extended periods.

Cooling areas should be arranged to prevent employees from unintentionally contacting hot metal.

Hot castings should be identified or otherwise controlled where their temperature is not obvious.

Appropriate tools and PPE should be used when handling hot castings.

Casting Cleaning and Finishing

Cleaning and finishing can involve:

• Chipping
• Grinding
• Cutting
• Sawing
• Abrasive blasting
• Shot blasting
• Gouging
• Welding
• Other finishing methods

These operations can generate silica, metal dust, fumes, noise, sparks, and flying particles.

Engineering controls should be used where appropriate.

Fettling

Fettling and casting-cleaning operations may expose employees to high concentrations of dust and noise.

Procedures should address:

• Ventilation
• Tool selection
• Abrasive wheels
• Eye and face protection
• Hearing protection
• Respiratory hazards
• Ergonomics

Castings should be securely positioned before work begins.

Grinding Safety

Grinding castings can expose employees to:

• Flying particles
• Abrasive-wheel failures
• Sparks
• Noise
• Metal dust
• Silica
• Vibration

Grinding equipment should be inspected and appropriately guarded.

Employees should use required eye and face protection.

Abrasive Wheel Safety

Abrasive wheels should be:

• Suitable for the equipment
• Properly rated
• Inspected
• Mounted correctly
• Appropriately guarded

Employees should not use damaged wheels.

Work rests and other protective components should be maintained as applicable.

Abrasive Blasting

Abrasive blasting may generate high concentrations of airborne dust and create severe noise and impact hazards.

Procedures should address:

• Blast media
• Ventilation
• Enclosures
• Respiratory protection
• PPE
• Noise
• Employee access
• Dust collection

Employees outside the blasting operation should also be protected from hazardous exposure.

Shot-Blast Equipment

Shot-blast machines should be guarded and maintained to prevent employee exposure to moving equipment and flying abrasive.

Doors and access points should be controlled to prevent hazardous operation while employees are exposed.

Maintenance should be performed under appropriate hazardous-energy-control procedures.

Metal Fumes and Dust

Foundry employees may be exposed to fumes or dust containing metals associated with the alloys being melted, poured, cut, ground, or finished.

Potential metals may include:

• Iron
• Manganese
• Nickel
• Chromium
• Copper
• Zinc
• Lead
• Aluminum
• Other alloying elements

The exposure profile should be determined by the metals and processes actually present.

Ferrous Foundries

Iron and steel foundries may have hazards associated with:

• High melting temperatures
• Silica
• Carbon monoxide
• Metal fumes
• Coke or combustion products
• Manganese
• Alloying metals
• Refractory materials

Controls should reflect the specific furnace and alloys used.

Nonferrous Foundries

Aluminum, brass, bronze, copper, and other nonferrous foundries may present different metal-fume, flux, chemical, and process hazards.

Employees should understand the hazards associated with the particular alloys and additives being used.

Ventilation and exposure monitoring should be based on actual contaminants.

Aluminum Foundry Safety

Aluminum foundries should give particular attention to moisture control around molten metal.

Procedures should address:

• Scrap condition
• Tools
• Furnace charging
• Ladles
• Dross
• Molten-metal transfer
• Pouring
• PPE

Only employees trained in applicable molten-aluminum hazards should perform melting and pouring work.

Brass and Bronze Foundries

Brass and bronze casting may involve copper, zinc, lead, tin, nickel, and other alloying elements.

Melting, pouring, and finishing operations should be evaluated for metal-fume and dust exposures.

Controls should reflect the actual alloy composition.

Carbon Monoxide

Combustion and foundry processes can create carbon monoxide exposure.

Potential sources may include:

• Furnaces
• Cupolas
• Burners
• Internal-combustion equipment
• Mold decomposition
• Poorly ventilated processes

Facilities should evaluate areas and processes where carbon monoxide could accumulate.

Industrial Ventilation

Effective ventilation is a critical foundry exposure control.

Systems may include:

• Local exhaust ventilation
• Furnace exhaust
• Pouring exhaust
• Shakeout ventilation
• Grinding booths
• Dust collectors
• General ventilation

Systems should be designed for the process and maintained in effective operating condition.

Ventilation Inspections

Ventilation systems should be inspected and maintained.

Employees should report:

• Damaged ductwork
• Missing hoods
• Poor capture
• Unusual dust
• Smoke accumulation
• Reduced airflow
• Dust collector problems

Production should not continue without evaluation when failure of a critical exposure-control system creates an uncontrolled hazard.

Industrial Hygiene

Foundry industrial-hygiene evaluations should consider the actual metals, molding materials, chemicals, and processes present.

Monitoring may be appropriate for:

• Silica
• Metal fumes
• Metal dust
• Carbon monoxide
• Chemical vapors
• Combustion products
• Noise
• Heat

Monitoring results should be used to determine appropriate controls, PPE, respiratory protection, medical surveillance, and training.

Respiratory Protection

Respiratory protection may be required for silica, metal fumes, dust, gases, vapors, or other airborne contaminants.

When respirators are required, the Respiratory Protection Program should address:

• Medical evaluation
• Respirator selection
• Fit testing
• Training
• Inspection
• Cleaning
• Storage
• Filter and cartridge replacement
• Program evaluation

Engineering controls should remain the primary method of exposure control where required and feasible.

Heat Stress

Foundry employees can experience substantial radiant and environmental heat exposure.

High-heat operations may include:

• Furnace tending
• Charging
• Tapping
• Ladle handling
• Pouring
• Shakeout
• Hot casting handling

Heat-stress procedures should address hydration, acclimatization, rest, employee monitoring, and appropriate controls.

Radiant Heat

Furnaces and molten metal can create intense radiant heat even when surrounding air temperatures are lower.

Controls may include:

• Heat shields
• Barriers
• Increased distance
• Mechanical handling
• Work-rest practices
• Appropriate protective clothing

Employees should be monitored for signs of heat-related illness.

Personal Protective Equipment

Foundry PPE should be selected through a hazard assessment and matched to the metal and task.

PPE may include:

• Safety glasses
• Goggles
• Face shields
• Hard hats
• Heat-resistant clothing
• Molten-metal protective clothing
• Gloves
• Protective footwear
• Leg protection
• Hearing protection
• Respiratory protection

PPE appropriate for routine machining may not provide adequate protection for molten-metal work.

Molten-Metal PPE

Clothing used around molten metal should be appropriate for the metal, temperature, and splash hazard.

PPE selection should consider:

• Heat resistance
• Flame resistance
• Molten-metal shedding
• Coverage
• Clothing design
• Foot protection
• Face and eye protection

Employees should understand how to wear PPE so molten metal is less likely to become trapped.

Hearing Conservation

Foundry noise may come from:

• Shakeout
• Grinding
• Chipping
• Blasting
• Pneumatic tools
• Conveyors
• Furnaces
• Material handling
• Ventilation systems

Noise exposures should be evaluated and controlled.

A Hearing Conservation Program should be implemented when required.

Machine Guarding

Foundries use mixers, mullers, conveyors, shakeout equipment, grinders, saws, presses, molding machines, blasting equipment, and other machinery.

Employees should be protected from:

• Nip points
• Rotating shafts
• Belts
• Pulleys
• Gears
• Chains
• Cutting points
• Reciprocating equipment

Guards and safety devices should remain in place during normal operation.

Automated Foundry Equipment

Automated molding, pouring, material-transfer, finishing, and robotic systems can expose employees to unexpected movement.

Safeguarding may include:

• Barriers
• Interlocked gates
• Presence-sensing devices
• Light curtains
• Safety controls
• Emergency stops

Employees should not bypass safeguards to clear jams or make adjustments.

Lockout/Tagout

Foundry machinery can contain:

• Electrical energy
• Mechanical energy
• Hydraulic pressure
• Pneumatic pressure
• Gravity
• Thermal energy
• Stored pressure

Authorized employees should follow applicable energy-control procedures before servicing equipment where unexpected startup or energy release could cause injury.

Stored Energy

Foundry equipment may retain energy after shutdown.

Examples include:

• Hydraulic pressure
• Pneumatic pressure
• Elevated components
• Springs
• Flywheels
• Conveyor tension
• Hot equipment
• Stored material

Stored energy should be relieved, restrained, blocked, dissipated, or otherwise controlled.

Furnace Maintenance

Furnace maintenance can expose employees to residual heat, refractory materials, electrical energy, fuel systems, confined spaces, and other hazards.

Before work begins:

• Shut down the furnace.
• Isolate hazardous energy.
• Control fuel sources.
• Allow appropriate cooling.
• Evaluate atmosphere where necessary.
• Establish safe access.

Employees should verify safe conditions before entering or working inside furnace equipment.

Refractory Maintenance

Refractory installation, removal, and repair can generate dust and expose employees to heat, silica-containing materials, fibers, chemicals, and falling material.

The refractory material should be evaluated before work begins.

Controls may include:

• Dust suppression
• Local ventilation
• Respiratory protection
• PPE
• Controlled removal methods
• Housekeeping

Confined Space Entry

Foundry confined spaces may include:

• Furnaces
• Pits
• Dust collectors
• Bins
• Hoppers
• Tanks
• Ductwork
• Process equipment

Spaces should be identified and evaluated before entry.

Permit-required confined spaces should be entered according to applicable procedures.

Pits and Below-Grade Areas

Foundries may contain furnace pits, conveyor pits, sand-system pits, and other below-grade areas.

Hazards may include:

• Restricted access
• Falling material
• Machinery
• Gases
• Carbon monoxide
• Water
• Hot material

Pits should be evaluated for both physical and atmospheric hazards.

Conveyor Safety

Conveyors may transport sand, molds, cores, castings, scrap, and other materials.

Employees should remain clear of:

• Nip points
• Pulleys
• Rollers
• Belts
• Chains
• Drives
• Moving material

Required guards should remain installed.

Conveyor Maintenance

Before maintenance:

• Shut down equipment.
• Isolate hazardous energy.
• Control stored energy.
• Secure elevated components.
• Verify isolation.

Employees should not rely solely on emergency-stop controls for energy isolation.

Cranes and Hoists

Foundries frequently use overhead cranes and hoists to move:

• Ladles
• Molten metal
• Castings
• Molds
• Scrap
• Furnace components
• Equipment

Only trained and authorized employees should operate cranes as required.

Equipment should be inspected and maintained.

Rigging

Rigging should be selected for the load, environment, and temperature.

Employees should inspect:

• Slings
• Chains
• Hooks
• Shackles
• Lifting devices

Damaged rigging should be removed from service.

Employees should remain clear of suspended loads.

Crane Movement Around Molten Metal

Crane operations involving molten metal require particular care.

Operators should:

• Maintain smooth control.
• Avoid sudden acceleration or stopping.
• Keep travel paths clear.
• Maintain communication.
• Keep unnecessary employees outside the area.

Equipment used for molten-metal handling should be suitable for the operation.

Forklift Safety

Forklifts may transport raw materials, molds, castings, scrap, finished products, and supplies.

Only trained and authorized employees should operate powered industrial trucks.

Operators should:

• Inspect equipment.
• Wear seat belts where provided.
• Maintain visibility.
• Observe capacity.
• Control speed.
• Remain alert to pedestrians.

Pedestrian and Mobile Equipment Safety

Foundry layouts can place pedestrians near forklifts, loaders, cranes, ladle carriers, and other equipment.

Controls may include:

• Marked walkways
• Barriers
• Restricted areas
• Mirrors
• Warning devices
• High-visibility apparel
• Traffic rules

Employees should avoid entering equipment blind spots.

Material Handling

Foundry materials can be extremely heavy and may include irregular castings, molds, cores, ingots, scrap, and tooling.

Mechanical handling should be used when practical.

Employees should avoid:

• Pinch points
• Suspended loads
• Unstable stacks
• Rolling materials
• Placing hands beneath unsupported loads

Casting Handling

Castings may remain hot and can have sharp edges, gates, risers, burrs, or irregular shapes.

Employees should:

• Determine whether castings have cooled sufficiently.
• Use appropriate gloves.
• Control sharp edges.
• Use mechanical assistance for heavy castings.
• Maintain stable storage.

Ergonomics

Foundry work can involve forceful exertion, repetitive motion, awkward postures, heavy lifting, vibration, and manual tool use.

Ergonomic evaluations should consider:

• Casting weight
• Workstation height
• Tool design
• Reaching
• Repetition
• Vibration
• Material positioning

Mechanical assistance and workstation improvements should be used where practical.

Hand and Power Tools

Foundry employees may use grinders, chippers, saws, pneumatic tools, drills, impact tools, and other equipment.

Tools should be:

• Inspected
• Properly guarded
• Maintained
• Appropriate for the task

Damaged tools should be removed from service.

Pneumatic Tools

Pneumatic chippers, grinders, and other tools may expose employees to noise, vibration, flying material, and hose hazards.

Employees should:

• Inspect hoses.
• Secure connections.
• Use required guards.
• Wear eye and face protection.
• Control air pressure.
• Protect hoses from damage.

Compressed air should not be directed at employees.

Welding, Cutting and Hot Work

Foundry maintenance and casting repair may involve welding, cutting, brazing, gouging, and grinding.

Hot-work procedures should address:

• Fire
• Metal fumes
• Sparks
• Combustible materials
• Compressed gases
• Ventilation
• PPE
• Fire watch

The specific metal being heated should be considered when evaluating fume hazards.

Compressed Gas Cylinders

Compressed gases should be:

• Properly identified
• Secured
• Protected from damage
• Stored appropriately
• Transported safely

Employees should inspect regulators, hoses, valves, and connections before use.

Electrical Safety

Foundry electrical hazards may involve furnaces, induction equipment, motors, conveyors, cranes, portable tools, and control panels.

Only qualified employees should perform specialized electrical work.

Procedures should address:

• De-energization
• Testing
• Electrical enclosures
• Grounding
• Damaged equipment
• Wet areas
• Temporary power

Hazard Communication

Foundries may use:

• Binders
• Resins
• Catalysts
• Fluxes
• Release agents
• Coatings
• Solvents
• Cleaning chemicals
• Lubricants
• Alloying materials

Employees should have access to Safety Data Sheets and receive appropriate chemical-hazard training.

Combustible Dust

Certain foundry materials, metal powders, dusts, or other finely divided combustible materials may create combustible-dust hazards.

The facility should evaluate materials and processes to determine whether combustible dust is present.

Where applicable, controls should address:

• Dust accumulation
• Ignition sources
• Dust collection
• Equipment design
• Housekeeping
• Hot work

Not every foundry has the same combustible-dust hazards.

Fire Prevention

Foundry fire hazards may involve:

• Molten metal
• Furnaces
• Fuel systems
• Flammable liquids
• Combustible materials
• Hot work
• Electrical equipment
• Dust

Fire-prevention procedures should reflect the specific facility hazards.

Employees should know alarm and evacuation procedures.

Spill Prevention

Foundry spills may involve:

• Molten metal
• Chemicals
• Oils
• Fuels
• Hydraulic fluids
• Binders
• Solvents

Response procedures should reflect the substance and hazard.

Employees should respond only within the limits of their training and assigned responsibilities.

Walking-Working Surfaces

Foundry floors can be affected by:

• Sand
• Metal debris
• Water
• Oil
• Scrap
• Hoses
• Cords
• Uneven surfaces

Travelways should be maintained as safely as practical.

Employees should promptly report hazardous walking surfaces.

Housekeeping

Good housekeeping is particularly important for controlling dust, trip hazards, fire hazards, and material accumulation.

Employees should keep:

• Aisles clear
• Floors orderly
• Emergency equipment accessible
• Electrical equipment accessible
• Workstations clean
• Scrap controlled

Housekeeping methods should not create additional airborne exposures.

Emergency Action Plan

Foundry emergency planning should address foreseeable events such as:

• Molten-metal spills
• Furnace emergencies
• Fires
• Explosions
• Chemical releases
• Electrical incidents
• Equipment failures
• Medical emergencies
• Severe weather

Employees should understand alarms, evacuation routes, assembly locations, and reporting procedures.

Furnace Emergency Response

Potential furnace emergencies may include:

• Cooling-system failure
• Refractory failure
• Electrical failure
• Fuel-system problems
• Molten-metal leakage
• Water intrusion

Employees should understand shutdown, evacuation, and notification procedures appropriate to the furnace.

First Aid and Burn Response

Foundries should prepare for thermal burns, chemical burns, eye injuries, cuts, crushing injuries, and other workplace emergencies.

Employees should know:

• How to summon assistance
• Location of first-aid supplies
• Location of emergency washing equipment
• Emergency communication procedures

Serious burns and other emergencies require prompt professional medical treatment.

Incident Reporting and Investigation

Employees should promptly report:

• Injuries
• Occupational illnesses
• Near misses
• Molten-metal incidents
• Equipment damage
• Fires
• Hazardous conditions

Incidents should be investigated to identify contributing and root causes.

Corrective actions should address equipment, procedures, training, supervision, engineering controls, maintenance, and other underlying factors as appropriate.

Foundry Safety Training

Employees should receive training appropriate to their assigned work and exposures.

Training may include:

• Molten-metal safety
• Furnace safety
• Ladle safety
• Silica exposure
• Metal fumes
• Heat stress
• PPE
• Machine guarding
• Lockout/tagout
• Crane and hoist safety
• Rigging
• Forklift safety
• Hazard communication
• Respiratory protection
• Hearing conservation
• Emergency procedures

Training should be documented as applicable and updated when processes, metals, equipment, chemicals, work assignments, or hazards change.

Building a Foundry Safety Manual

A Foundry Safety Manual should be customized to the metals, molding systems, furnaces, casting processes, and finishing operations used at the facility rather than relying solely on a generic Manufacturing Safety Manual or Metal Fabrication Safety Manual.

An iron or steel foundry using sand molds, melting furnaces, overhead ladles, shakeout equipment, sand reclamation, grinders, and blasting equipment may require extensive programs for silica, molten metal, heat, metal fumes, cranes, machine guarding, hazardous energy, and hearing conservation.

An aluminum foundry may place additional emphasis on moisture control, scrap inspection, molten-metal handling, dross operations, fluxes, furnace charging, and alloy-specific exposure hazards.

A brass, bronze, or other nonferrous foundry may require additional evaluation of copper, zinc, lead, nickel, or other metals depending on the alloys being processed.

The manual should reflect the facility’s metals, alloys, furnaces, molds and cores, sand systems, pouring operations, casting-cleaning processes, industrial-hygiene exposures, material-handling equipment, maintenance activities, employees, and emergency hazards.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, industrial-hygiene controls, exposure monitoring, JSAs, equipment inspections, incident investigations, emergency planning, and the company’s overall safety-management system.

Customized Foundry Safety Manuals

Get a Foundry Safety Manual customized for your melting furnaces, molten-metal operations, ladles, molds and cores, sand systems, pouring, shakeout, casting cleaning, grinding, silica exposures, metal fumes, cranes and hoists, maintenance activities, and other foundry hazards.