ASTM E2349-05

Standard Practice for Safety Requirements in Metal Casting Operations: Sand Preparation, Molding, and Core Making; Melting and Pouring; and Cleaning and Finishing

ABSTRACT
This practice covers the safety requirements for applying the design, construction, and operation of machinery and equipment used in metal casting operations. These operations include sand preparation, molding, and core making; melting and pouring; and cleaning and finishing. This practice does not apply to die casting operations. This aim of this specification is to minimize the possibility of injury to operating and maintenance personnel while working on, or in the vicinity of, the specified equipment.
SCOPE
1.1 This practice covers the requirements of applying the design, construction, and operation of the machinery and equipment used in metal casting operations-sand preparation, molding and core making, melting and pouring, and cleaning and finishing. This practice does not apply to die casting operations.
1.2 Purpose—The requirements of this practice, including the training of supervisors and employees, are intended to minimize the possibility of injury to operating and maintenance personnel while working on, or in the vicinity of, the specified equipment. Compliance with this practice, in conjunction with OSHA regulations, provides a relatively safe environment, which is a fundamental requisite in helping to prevent occupational injuries.
1.3 Application
1.3.1 New Installations—After the date of publication, all new installations within the scope of this specification shall be in conformance with its requirements. Any existing machine installation moved to a new plant or another location in the same plant is deemed a new installation when it is installed in the new location. However, an existing installed machine (former installation) that is moved for a short distance, for example, to provide additional aisle space, is not deemed to be a new installation.
1.3.2 Existing Installations—After the approval date of this practice, installations existing on, or before, this date, shall be modified as necessary to be in conformance with all requirements of this practice. Where it is not practical to modify an existing facility in conformance with this practice, deficiencies shall be noted and plans for compliance shall be included in any future facility or equipment changes. Those facilities and equipment on order or in the process of construction on the date of publication of this practice shall be considered as an existing installation. This practice applies to existing equipment if it lacks the necessary employee protection (personal protective equipment or administrative controls).
1.4 The values stated in inch/pound units are to be regarded as the standard. The values in brackets are for information only.
1.5 The text of this practice references notes and footnotes which provide explanatory material. These notes and footnotes (excluding those in tables and figures) shall not be considered as requirements of the standard.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and to determine the applicability of regulatory limitations prior to use.

General Information

• Status: Historical
• Publication Date: 30-Apr-2005
• ICS: 77.180 - Equipment for the metallurgical industry
• Technical Committee: E34 - Occupational Health and Safety

Relations

• Replaced By: ASTM E2349-09 - Standard Practice for Safety Requirements in Metal Casting Operations: Sand Preparation, Molding, and Core Making; Melting and Pouring; and Cleaning and Finishing
• Effective Date: 01-Jul-2009
• Referred By: ASTM A74-21 - Standard Specification for Cast Iron Soil Pipe and Fittings
• Effective Date: 01-May-2005
• Referred By: ASTM A1111-22 - Standard Specification for Cast Iron Closet Flanges for Use with Cast Iron Soil Pipe and Fittings in Gravity Flow Plumbing Drain, Waste, and Vent Sanitary Applications
• Effective Date: 01-May-2005
• Referred By: ASTM E1542-21 - Standard Terminology Relating to Occupational Health and Safety
• Effective Date: 01-May-2005
• Referred By: ASTM A888-21a - Standard Specification for Hubless Cast Iron Soil Pipe and Fittings for Sanitary and Storm Drain, Waste, and Vent Piping Applications
• Effective Date: 01-May-2005

Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: E 2349 – 05
Standard Practice for
Safety Requirements in Metal Casting Operations: Sand
Preparation, Molding, and Core Making; Melting and
Pouring; and Cleaning and Finishing
This standard is issued under the fixed designation E 2349; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
INTRODUCTION
This practice is part of a project started in 1972 under the sponsorship of the American Foundry
Society, Inc. Standard for Safety Requirements in Metal Casting Operations—Sand Preparation,
Molding, and Core Making; Melting and Pouring; and Cleaning and Finishing.
The metal casting industry shares safety considerations with many other industries requiring the
movement of heavy objects, the use of large ovens and melt furnaces, and processing of hot materials.
In addition, there are safety considerations common to all industries. The present trend is towards the
development of industry-wide standards wherever the need for safety considerations exists. This
practice, therefore, is limited to safety considerations of special importance in the metal casting
industry operations in which general standards do not exist or are not considered adequate. Operating
rules are not included in this practice unless they are vital to safety.
Compliance with this practice should provide a relatively safe environment, which is a fundamental
requirement in preventing occupational injuries.
Contents
Introduction 6.3 Hazardous Zone Guarding
1. Scope 6.4 Hazardous Zone Protective Devices
2. Referenced Documents 7. Operation of Equipment—General Requirements
3. Terminology 7.1 Employer’s Responsibility
4. Materials and Manufacture 7.2 Employee’s Responsibility
4.1 Responsibility 8. Sand Preparation, Molding, and Coremaking
4.2 Inherent Hazards 8.1 Specific Equipment Safeguards—Sand Preparation, Molding, and Coremak-
ing
4.3 Installation 8.2 Operation Procedures for Sand Preparation, Molding, and Coremaking
4.4 Power Requirements 9. Melting and Pouring
4.5 Electrical Ground Faults 9.1 Cupolas
4.6 Fluid Power Off 9.2 Electric Furnaces - Induction Melting and Induction Holding
4.7 Electrical Equipment Grounding 9.3 Electric Furnaces—Direct Arc Furnaces
4.8 Fluid Exhaust (Gas or Liquid) 9.4 Ladles
5. Care of Equipment—General Provisions 9.5 Molten Metal Handling and Pouring Equipment
5.1 Instructions 9.6 Maintenance and Inspection
5.2 Installation 9.7 Molten Metal Treatment
5.3 Inspection and Preventive Maintenance 9.8 Specific Material Handling Equipment
5.4 Maintenance Personnel Training and Experience 9.9 Ladle Use
5.5 Startup Procedure 9.10 Overhead Handling of Molten Material
5.6 Shutdown Procedure 10. Cleaning and Finishing
5.7 Troubleshooting, Maintenance and Repair 10.1 Care of Cleaning and Finishing Equipment
6. Safeguards—General Requirements 10.2 Specific Equipment Safeguards—Cleaning and Finishing
6.1 Responsibility for Safeguarding 10.3 Operating Procedures for Cleaning and Finishing Equipment
6.2 Guarding Within the Operator’s Work Zone 11. Keywords
1. Scope
1.1 This practice covers the requirements of applying the
This practice is under the jurisdiction of ASTM Committee E34 on Occupa-
design, construction, and operation of the machinery and
tional Health and Safety and is the direct responsibility of Subcommittee E34.20 on
equipment used in metal casting operations—sand preparation,
Foundry Safety and Health.
Current edition approved May 1, 2005. Published June 2005.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
E2349–05
molding and core making, melting and pouring, and cleaning 2.2 ANSI Standards:
and finishing. This practice does not apply to die casting ANSI A12.64.1 Safety Requirements for Workplace, Floor
operations. and Wall Openings, Stairs and Railing Systems
1.2 Purpose—The requirements of this practice, including ANSIA58.1 Minimum Design Load in Buildings and Other
Structures
the training of supervisors and employees, are intended to
minimizethepossibilityofinjurytooperatingandmaintenance ANSI B5.35 Machine Mounting for Abrasive Discs and
Plate Mounted Wheels
personnel while working on, or in the vicinity of, the specified
equipment. Compliance with this practice, in conjunction with ANSI B 11.6 Safety Requirements for Manual Turning
Machines with or without Automatic Control
OSHA regulations, provides a relatively safe environment,
which is a fundamental requisite in helping to prevent occu- ANSI B7.1 Safety Requirements for the Use, Care and
Protection of Abrasive Wheels.
pational injuries.
ANSI B11.9 Grinding Machines, Safety Requirements for
1.3 Application
the Construction, Care and Use of
1.3.1 New Installations—After the date of publication, all
ANSI B11 TR3 Risk Assessment and Risk Reduction—A
new installations within the scope of this specification shall be
Guide to Estimate, Evaluate and Reduce RisksAssociated
in conformance with its requirements. Any existing machine
with Machine Tools
installation moved to a new plant or another location in the
ANSI B15.1 Mechanical Power Transmission Apparatus
same plant is deemed a new installation when it is installed in
ANSI B20.1 Safety Standard for Conveyors and Related
the new location. However, an existing installed machine
Equipment (ASME B20.1)
(former installation) that is moved for a short distance, for
ANSI/ASME B30.2 Overhead and Gantry Cranes (Top
example, to provide additional aisle space, is not deemed to be
Running, Bridge, Single or Multiple Girder Top Running
a new installation.
Trolley Hoist)
1.3.2 Existing Installations—After the approval date of this
ANSI/ASME B30.9 Slings
practice, installations existing on, or before, this date, shall be
ANSI/ASME B30.10 Hooks
modified as necessary to be in conformance with all require-
ANSI/ASME B30.11 Monorails and Underhung Cranes
ments of this practice. Where it is not practical to modify an
ANSI/ASME B30.20 Below-the-hook Lifting Devices
existing facility in conformance with this practice, deficiencies
ANSI B107.4 Driving & Spindle Ends for Portable Hand,
shall be noted and plans for compliance shall be included in
Air and Electric Tools (Percussion Tools Excluded)
any future facility or equipment changes. Those facilities and
ANSI B186.1 Portable Air tools
equipment on order or in the process of construction on the
ANSIZ9.2 FundamentalsGoverningtheDesignandOpera-
date of publication of this practice shall be considered as an
tion of Local Exhaust Ventilation Systems
existing installation. This practice applies to existing equip-
ANSI Z9.4 Ventilation and Safe Practices of Abrasive
ment if it lacks the necessary employee protection (personal
Blasting Operations
protective equipment or administrative controls).
ANSI Z33.1 Standard for the Installation of Blower and
1.4 The values stated in inch/pound units are to be regarded
Exhaust Systems (NFPA 91)
asthestandard.Thevaluesinbracketsareforinformationonly.
ANSI Z43.1 Ventilation Control of Grinding, Polishing/
1.5 The text of this practice references notes and footnotes
Buffing
which provide explanatory material.These notes and footnotes
ANSI Z244.1 Personnel Protection—Lockout/Tagout of
(excluding those in tables and figures) shall not be considered
Energy Sources—Minimum Safety Requirements
as requirements of the standard.
ANSI Z490.1 Accepted Practices in Safety, Health and
1.6 This standard does not purport to address all of the
Environmental Training
safety concerns, if any, associated with its use. It is the
ANSI Z535.1 Safety Color Code
responsibility of the user of this standard to establish appro-
ANSI Z535.2 Environmental and Facility Safety Signs
priate safety and health practices and to determine the
ANSI Z535.3 Criteria for Safety Symbols
applicability of regulatory limitations prior to use.
ANSI Z535.4 Product Safety Signs and Labels
ANSI Z535.5 Accident Prevention Tags
2. Referenced Documents
2.3 NFPA Standards:
2.1 ASTM Standards:
NFPA 49 Fire Protection Guide to Hazardous Materials
F 1002 Specification for Protective Clothing for Use by
NFPA 68 Guide for Venting of Deflagrations
Workers Exposed to Specific Molten Substances and Re-
NFPA 70 National Electrical Code
lated Thermal Hazards
NFPA 86 Standard for Ovens and Furnaces
F 1449 Guide for Care and Maintenance of Flame Resistant
NFPA 480 Standard for Storage and Handling of Magne-
and Thermally Protective Clothing
sium
2 3 rd th
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Available from the American National Standards Institute, 25 W. 43 St., 4
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Floor, New York, NY 10036.
Standards volume information, refer to the standard’s Document Summary page on Available from the National Fire ProtectionAssociation, 1 Batterymarch Park,
the ASTM website. Quincy, MA 02269-9101.
E2349–05
2.4 Occupational Safety and Health Administration: 3.10 backcharge, n—recharging a furnace to produce the
29 CFR 1910 Code of Federal Regulations, Part 1910 desired heat size.
General Industry
3.11 bail/spreader, n—hoop or arched connection between
29 CFR 1910.23 Guarding Floor and Wall Openings and
the crane hook and ladle or between crane hook and ladle
Holes
trunnions.
29 CFR 1910.94(a) Ventilation—Abrasive Blasting
3.12 barrier guard—see adjustable barrier guard, fixed
29 CFR 1910.145 Specification for Accident Prevention
barrier guard, and interlocked barrier guard
Signs and Tags
3.13 blast, n—air under pressure directed into a cupola or
29 CFR 1910.146 Permit required Confined Spaces
furnace for supporting combustion.
29 CFR 1910.147 Control of Hazardous Energy
3.14 blast compartment, n—that portion of the blasting
(LOCKOUT/TAGOUT)
enclosure that contains the blasting media propulsion device.
29 CFR 1910.184 Slings
3.15 blow plate, n—plate affixed to the magazine or blow
29 CFR 1910.215 Abrasive Wheel Machinery
head of a core- or mold-blowing machine having holes or slots
29 CFR 1910.217 Mechanical Power Presses
through which sand or other media in the magazine or blow
2.5 American Foundry Society (AFS)
head passes into the core or mold cavity or around the pattern
Recommended Clothing and Personal Protective Equip-
when air or other gas pressure is applied to the machine.
ment (PPE) for Metal Melting and Pouring Operations
3.16 bottom discharge (pour, tap) ladle, n—ladlethathasits
Managing the Foundry Indoor Air Environment
molten metal contents discharged through an opening in the
bottom.
3. Terminology
3.17 channel furnace, n—electric induction furnace in
3.1 abrasive blasting, n—operation in which an abrasive is
which heat is electrically induced in the metal in a refractory
forcibly applied to a surface by pneumatic or hydraulic
channel.
pressure or centrifugal force.
3.18 charge, n—material introduced into a melting furnace
3.2 acoustical treatment, n—means by which the level of
for the production of molten metal.
sound, noise, or audible vibration may be attenuated (reduced).
3.19 charge preheater, n—device for preheating charge
3.3 adjustable barrier guard, n—physical barrier with ad-
materials before they are added to a furnace.
justablesectionsthatpreventsentryofanypartofthebodyinto
3.20 charging, v—process of adding a charge to a furnace.
thehazardouszonebyreachingthrough,over,under,oraround
3.21 clamp frame, n—moving frame on a core-blowing
the barrier. The adjustable sections allow different jobs to be
machinethatmovesthecoreboxandpressesitagainsttheblow
run on the equipment.
plate.
3.3.1 Discussion—This type of guard requires close super-
3.22 clearance line, n—line, which marks the distance,
vision of use and adjustment or inadequate protection may
required to prevent contact between a guard(s) and moving
result. It shall be the responsibility of the employer to establish
parts.
and follow a program of periodic and regular inspection of
power press and auxiliary equipment. Refer to 29 CFR 3.23 control circuit (electrical), n—circuit of a control
apparatus or system that carries the electric signals directing
1910.217(e).
3.4 airless blast cleaning, n—form of abrasive blast in the performance of the controller, but does not carry the main
power current.
which the abrasive media is propelled by centrifugal force.
3.5 anti-tie-down, n—requires that the two-hand controls
3.24 controller, n—deviceorgroupofdevicesthatservesto
function only when both initiators have been released just govern, in some predetermined manner, the electric power
before operation. Unauthorized tying down of one initiator to
delivered to the apparatus to which it is connected.
permit one-hand operation by the other initiator prevents
3.25 core, n—preformed aggregate or collapsible insert
operation (see 3.151 and 3.152).
placed in a mold to shape the interior or that part of a casting
3.6 arc furnace, n—see direct arc furnace and indirect arc
that cannot be shaped by the pattern.
furnace
3.26 core- or mold-blowing or shooting machine,
3.7 auger, n—rotating screw used to mix, or transport, or
n—machine for injecting sand or other media into the core or
both sand, clay, or other media used in core and mold making.
mold cavity by means of compressed air or other gas.
3.8 automatic, adv—each function in the machine cycle is
3.27 core binder(s), n—any material, liquid or solid, which
initiated by the previous cycle and is automatically performed
is used to bond core aggregates.
and sequenced, including load, unload, and repeat cycle.
3.28 corebox, n—a (wood, metal, or plastic) structure, the
3.9 automatic mode, n—method of operation in which each
cavity of which has the shape of the desired core that is to be
functionintheequipmentcycleisautomaticallysequencedand
made therein.
repeated.
3.29 corelessfurnace,n—electricinductionfurnaceconsist-
ing of an induction coil surrounding a crucible or refractory
lining in which metal is melted or molten metal is retained.
Available from the Occupational Safety and Health Administration, 200
3.30 counterweight, n—weight that corrects a state of un-
Constitution Ave., NW, Washington, DC 20210.
balance and establishes static equilibrium.
Available from the American Foundry Society. 505 State St., Des Plaines, IL
60016. 3.31 crane ladle, n—ladle handled by an overhead crane.
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3.32 crucible, n—container used for the melting, holding, by location, or other protective devices, so as to reduce the
and pouring of metal. possible ris
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