GANPAT UNIVERSITY

U. V. PATEL COLLEGE OF ENGINEERING

MECHANICAL ENGINEERING DEPARTMENT
B. TECH VII SEM MECHANICAL
2ME71PE1: FOUNDRY TECHNOLOGY
PRACTICAL – 1

AIM: - To study about safety norms in foundry industry.

Introduction: To recognize the importance of safety in a foundry and execute proper safety
measures in carrying out casting processes.

A. Safety norms of the foundry:

Purpose: The purpose of this compliance code is to provide practical guidance on how employers
who undertake foundry work can meet their duties under the Occupational Health and Safety Act
2004 (the OHS Act) and Occupational Health and Safety Regulations 2007 (the Regulations).

B. Foundry hazards:

Molten metal explosions: Steam explosions are caused by the introduction of a moisture into
molten metal.

Chemical explosions: Chemical explosions occur through the introduction of reactive chemical
substances to molten metal directly or as a contaminant in charge material.

Heat stress: Working in hot conditions is hazardous. Health effects range from discomfort or
heat rash to heat exhaustion or heat stroke resulting in permanent damage or death. Heat stress
can harm without the worker being aware of the degree of effect until it is almost too late. It
affects concentration, perception and decision making, so heat stress is also dangerous in less
obvious ways.

Burns: Burns are one of the major types of injuries in molten metal foundries and are generally
caused by contact with hot surfaces, radiation or molten metal splashing.
Light radiation: Eye disorders and skin burns may be caused by intense ultraviolet and infrared
radiation from molten metal in furnaces, particularly around pouring areas and in welding
operations. Bystanders and passersby also need to be protected, preferably by exclusion.

Hazardous substances: Hazardous substances such as lead, amines, formaldehyde, toluene,

phenol, furfuryl alcohol and isocyanates are substances that can harm the health of people
exposed to them. They can be inhaled, swallowed or absorbed through the skin, and employees
can suffer immediate or long-term health effects.
Exposure may cause irritation, chemical burns, cancer, birth defects or diseases of certain organs
such as the lungs, liver, kidneys and nervous system.

Hazardous wastes: Legislative controls exist for the safe transport, storage and disposal of
hazardous waste. Where no legislative controls apply, a safe means of transport and disposal
(having regard to the nature of the hazard) needs to be employed (e.g. sealed, marked
containers suitably protected from possible damage and able to be handled safely).

Dangerous goods: Dangerous goods such as carbon dioxide, formaldehyde, oxygen, Sulphur
dioxide and xylene are hazardous for a variety of reasons – they may be highly flammable,
explosive, corrosive, acutely toxic, asphyxiant or highly reactive according to class. They are
readily identifiable by class diamonds on the labels.

Slips, trips and falls: Slips, trips and falls are a common hazard in most workplaces, with
consequences ranging from mild.

Manual handling: Manual handling tasks are those where force is exerted by a person to lift,
lower, push, pull, carry or otherwise move, hold or restrain any object. These occur during
pattern and core making, loading furnaces, molding, fettling, dispatch, inspection and surface
coating.

Machinery and equipment (plant): Machinery and equipment are used in pattern and core
making as well as casting and molding. Plant such as cranes, hoists, forklifts and conveyors are
also used as mechanical handling devices within foundries.

Mechanical hazards: Mechanical hazards include hard surfaces coming together and
scissoring action. Risks include entanglement, crushing, severing, cutting and slips, trips and
falls.
C. Non - mechanical hazards

Noise: Noise levels in excess of 85 decibels (dB(A)) averaged over eight hours, or a weight
peak hold sound pressure reading of 140 dB(C) can result in hearing loss. Pattern and core
making, molding, knockout and cleaning operations, fettling and some furnaces are among the
equipment and processes that produce noise levels in excess of the acceptable standard. Regular
exposure to excessive noise can damage the inner ear and cause tinnitus leading to difficulties
in communications.

Vibration: Whole body (1–80 Hz) vibration takes place during shake out, sand-slinging, on
forklifts, cranes and during pneumatic ramming operations. The adverse effects of whole-body
vibration include increased blood pressure and heart problems, nervous disorders, stomach
problems as well as joint and spine injuries.

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

Machinery that may cause non-mechanical injury: Abrasive blasting and rumbling present
hazards to employees from airborne contaminants and noise.

Access hazards: Access hazards are often complex, involving several risks at the same time,
such as chemical dosing in confined spaces or working at height.

D. Personal protective equipment (PPE) in the foundry

• Primary protective clothing is used for specific hazardous tasks then removed. It provides
protection from hazards such as metal splash and radiant heat. The garments need to be made
from inherently fire-retardant fabrics to ensure their protective properties are intact as long as
the garment is intact. They need to be comfortable to wear and breathable in very extreme work
conditions. Leather options offer some durability and protective benefits but can compromise
comfort and add to heat stress in certain situations.

• Secondary protective clothing is all-day/everyday clothing. The clothing needs to be fire-

retardant and the choice of inherent or treated can take comfort and cost into account, but these
garments are the last defense for the body if primary protection fails. A cotton fabric is the
minimum requirement, but specially treated cotton or wool fabric is recommended.
Primary and secondary PPE
Primary PPE Secondary PPE
for molten metal work for general foundry work
(in addition to secondary PPE)
HEAD
Use helmets where there is potential for items to fall from height or where work takes place
above head height (egg on a mezzanine). Industrial safety helmets should be considered.
Where tasks result in dust or particulates, a head covering should be considered.

EARS
The factors that need to be taken into account when selecting hearing protectors need to
include compliance with AS 1270, level of noise, the wearer (e.g. personal characteristics,
comfort), communication requirements, and compatibility with the job/workplace. Guidance
on hearing protectors is provided in AS/NZS 1269.3.

EYES AND FACE EYES AND FACE

Face shields with neck protection. Industrial safety glasses with side shields
are the minimum.

RESPIRATORY
Respiratory protective devices (RPD) used need to comply with AS/NZS 1716. The type of
respirator selected needs to take into account the operator (i.e. facial hair, physiological and
psychological factors), the task (i.e. how the job is done, duration, frequency) and the
substance (i.e. type of contaminant, concentration). The standard AS/NZS 1715 provides
guidance on the selection, use and maintenance of respire- tory protective devices. Guidance
can also be obtained from suppliers of respiratory protective equipment.
TRUNK AND ARMS TRUNK AND ARMS
A jacket of leather or other suitably resistant Long-sleeved shirt made from flame- resistant
material must be worn outside all other fabric such as wool, heavy cotton drill, Fire
clothing. It must be free of features such as wear, Tuff Weld and Indura, or fabrics with
cuffs and pockets that may trap molten metal. flame-retardant coatings such as Flame
It must be worn properly and fastened at all Shield, aramid or Trevira CS. Employers
times. must provide reflective clothing where there
is a risk radiation and heat may affect health.
Garments need to fasten at the neck and
wrists to prevent molten metal splashes, dust,
chemicals and other substances from entering
through the collar and cuffs.

HANDS HANDS
Heat-resistant Kevlar or heavy leather HANDS
gauntlets that cover the lower part of arm. Gloves selected need to take into account the
hazard (e.g.-burns, abrasion, chemicals,
cuts), the work environment and the wearer
(e.g. fit, comfort, dexterity).

LEGS LEGS
Where risk of molten metal spills or splashes Heat-resistant trousers.
exists, trousers of leather or other suitably
resistant materials must be worn. The trousers
need to cover the top of the footwear and be
free of features such as cuffs and pockets that
may trap molten metal.

FEET
Employees must wear safety footwear at all times in the workplace unless a legally qualified
medical practitioner certifies that wearing safety footwear would injure the wearer. In such
cases, the reason for such an opinion must be given and the most appropriate alternative
protective equipment sought.
PPE commonly used in foundry; from left to right: heat resistant glove, safety shoe, leather
apron, faces shields.