SAFE PRACTICE Safety Gear On the Melt Deck A MODERN CASTING STAFF REPORT T
oo often, workers in melting and pouring operations wear insuffi- cient protective gear. While this
is a danger that encompasses all types of metalcasting, Enkei America’s Ted Schorn recently provided some insight focusing specifically on steel. Te impli- cations could be reasonably applied to a wide variety of casting facilities. In his presentation at the 2013 AFS
Metalcasting Congress held in St. Louis, “Peeking Behind the Curtain: Steel Foundry Safety Statistics and Observa- tions,” Schorn discussed the events or ex- posures leading to days away from work in steel casting facilities, according to the Occupational Safety & Health Admin- istration (OSHA). Of these, contact with temperature extremes led the pack at nearly 18% in 2010. Overexertion and being struck by an object or equipment were about even in second and third place. Hot metal injuries accounted for about 17% of Days Away, Restricted and Transferred (DART) incidents. “Tere is some overall progress
on safety evident in the Total Case Incident Rate (TCIR), but no discern- ible trend of improvement in DART or Lost Time Case Incident Rate (LCIR),” Schorn said. “Tis is contrary to the clear trend in general manufac- turing. Despite improvement in safety, overall rates are roughly double those of general manufacturing.” Schorn noted decision-making is a
strong factor in safety. Training is criti- cal to ensuring worker safety, as well as planning by management and the provision of adequate workplace and personal protective equipment (PPE). Required and recommended PPE
varies across different types of metalcast- ing operations. Te American Foundry Society’s Safety & Health Committee (10-Q) compiled a “PPE Guide for Metalcasting Operations” in 2012 that offers the following suggestions for melt- ing and pouring. Secondary Protection—clothing or
personal protective equipment designed as basic protection for continuous use in areas where intermittent exposure to hazards is possible:
Proper safety gear is essential to preventing injuries in melting and pouring operations. September 2013 MODERN CASTING | 49
• 100% cotton or wool socks. • 100% cotton undergarments. • 100% cotton or wool outer garments. • Safety glasses with side protection. • Leather safety shoes with toe protec- tion and a smooth toe. Hearing protection and respiratory
protection may be necessary depend- ing on degree of exposure, and ad- ditional primary protection is required for employees in a hazard zone (i.e., near a furnace or ladle). Primary Protection—clothing
or PPE designed for activities where significant exposure to hazards such as molten metal splash, radiant heat, flame, noise or flying particles is likely to occur: • Body/limbs: Aluminized or other standard-approved (ASTM F1002) material coats, jackets, aprons, cape/ sleeves/bib, leggings, chaps, spats.
• Eyes: Goggles, full face shield, tinted glasses.
• Head: Hard hat, cotton or wool cap, aluminized hood.
• Hand: Heat resistant mitts, cover mitts, cover pads, gloves.
• Foot: Metatarsal safety shoes, heat resistant soles.
• Hearing: Ear plugs, earmuffs, ear caps. • Respiratory: Half mask or full face- piece respirator, filtering or powered air-purifying respirator, air-supplied helmet or hood. Te committee recommends per-
forming a thorough hazard assessment to determine the specific PPE required based on OSHA and American Na- tional Standards Institute regulations and NIOSH certifications. Material Safety Data Sheets also can provide key guidelines for hazardous ingredients and recommended precautions.
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