Foundry Operations

                       A SAFETY TALK FOR

                      DISCUSSION LEADERS



This safety talk is designed for discussion leaders to use in

preparing safety meetings.



Set a specific time and date for your safety meeting.  Publicize

your meeting so everyone involved will be sure to attend.



Review this safety talk before the meeting and become familiar with

its content.  Make notes about the points made in this talk that

pertain to your workplace.  You should be able to present the

material in your own words and lead the discussion without reading

it.



Seating space is not absolutely necessary, but arrangements should

be made so that those attending can easily see and hear the

presentation.



Collect whatever materials and props you will need ahead of time. 

Try to use equipment in your workplace to demonstrate your points.





                      DURING THE MEETING



Give the safety talk in your own words.  Use the printed talk

merely as a guide.



The purpose of a safety meeting is to initiate discussion of safety

problems and provide solutions to those problems.  Encourage

employees to discuss hazards or potential hazards the encounter on

the job. Ask them to suggest ways to improve safety in their area.



Don't let the meeting turn into a gripe session about unrelated

topics.  As discussion leader, its your job to make sure the topic

is safety.  Discussing other topics wastes time and can ruin the

effectiveness of your safety meeting.



At the end of the meeting, ask employees to sign a sheet on the

back of this talk as a record that they attended the safety

meeting.  Keep this talk on file for your records.















Foundry Operations



Most of us know the safety rules that apply to work in foundries,

but let's review these practices so we don't forget them.



The very nature of foundry work is hazardous--if things are not

done properly or if equipment is neglected and not checked for

malfunctions.  Clutter on the floor increases the chance for

accidents, so keep the floors and aisles as clean as possible.



Carefully check all cranes, hoists and lifts, including chains,

cables, hooks and links.  Secure large copes so they cannot fall

over.



Before using crucibles, bring them up to heat gradually. Rapid

increases or decreases in temperature are dangerous. Store the

crucibles where they cannot attract moisture, because even a small

amount of moisture can cause steam--and an explosion. Don't fill

crucibles too full; metal expands when heated and can crack a

crucible. Handle crucibles carefully to avoid spills.



Be sure the tongs fit the crucible and that the crucible fits the

shank.



Never put cold metal into molten metal; let it warm up first.



Never pour molten metal into a crucible that could have moisture in

it.



When lighting a gas-fired furnace, light a taper or a long match,

turn on the gas, light it and then adjust the air intake until the

flame is burning properly. Keep your face away from the opening.

When shutting down the furnace, turn these off first.



Check the pouring ladles and reline or fix them if necessary. Be

sure the ladles are dried out before using them.



Make sure the ladles fit the shank; the shank should be turned with

the side of the taper up when you insert the ladle. Ladle lips

should be at 90 degree angles to the shank center line.



Wear approved eye protection, aprons, leggings and gloves.



Be sure that hand ladles are equipped with a metal shield. Do not

fill bull ladles or hand ladles too full. Do not run or back up

with a ladle of metal.



When swigging castings on abrasive wheels or using hand grinders,

always wear approved eye protection.



Grinding wheel rests should be l/8 inch from the wheel. Never

adjust the wheel when it is in motion.



Don't use the side of the wheel for grinding--the stress may cause

the wheel to crack and explode, or the casting may lodge between

the guard and the wheel.



Do not station the rest below the center of the wheel.



In larger foundries where overhead cranes carry crucibles of molten

metal or heavy castings, pay strict attention to all warning

signals and procedures.



Where respirators are required, be sure you are using the proper

and approved type for the atmosphere in which you are working. It

is the company's responsibility to provide the respirator, but it's

your responsibility to wear it.

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