Foundry safety, health and environment
Domain 1 - Foundry safety, health and environment
This domain tests hazard recognition in a ferrous foundry, correct personal protective equipment, safe handling of molten metal and environmental control of sand, fume and waste.
Main hazards
- Molten iron at about 1300–1400 °C and steel at 1550–1650 °C causes deep burns; trapped moisture flashes to steam and ejects metal.
- Respirable crystalline silica comes from dry sand, moulding, knockout and fettling.
- Cupola and furnace gases include carbon monoxide; welding and pouring produce metal fume.
- Heat stress, noise, crane loads, heavy flasks and hand tools add mechanical risks.
Controls
Wear foundry boots, leggings, apron, helmet, face shield, dry leather gloves, ear defenders and suitable respiratory protection. Keep floors dry, preheat ladles and tools, and never add wet scrap to molten metal. Use local exhaust ventilation, dust extraction, CO monitors and sand reclamation; dispose of waste sand and slag to approved sites.
Worked example
A moulder sees water on the floor beside a full pouring ladle. The correct response is to stop the pour, move the ladle to a dry area and dry or preheat tools. Water under molten metal turns to steam and expands roughly 1 600 times, throwing metal. Wearing a wet glove creates the same explosion risk. Cooling a hot floor with a hose is therefore prohibited near molten metal.
Traps
Do not treat leather gloves or a face shield as optional; do not use compressed air to clean skin or clothing; do not assume invisible fume is harmless. “Wet down the floor to settle dust” fails when the water reaches a ladle. Report leaks, cracked ladles and damaged PPE before starting the shift.