Foundry Operations Toolbox Talk

Before the Toolbox Talk

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.

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 a discussion of safety problems and provide solutions to those problems. Encourage employees to discuss hazards or potential hazards they 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 a discussion leader, it’s your job to make sure the topic is safe. Discussing other topics wastes time and can ruin the effectiveness of your safety meeting.

Toolbox Talk: 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 the 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 centerline.
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.

Interactive Discussion

1. Have you or someone you know been injured or nearly injured while carrying out this activity? What happened?

2. How can we stay safe today?

3. What do we do at the worksite to prevent injuries related to this activity?

After the Toolbox Talk

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.

References

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