ASTM E2349-19

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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

General Information

• Status: Published
• Publication Date: 28-Feb-2019
• ICS: 77.180 - Equipment for the metallurgical industry
• Technical Committee: E34 - Occupational Health and Safety
• Drafting Committee: E34.10 - Industrial Safety

Relations

• Replaces: ASTM E2349-18 - 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-Mar-2019
• Refers: ASTM F1449-20 - Standard Guide for Industrial Laundering Care and Maintenance of Flame Resistant or Arc Rated Clothing
• Effective Date: 01-Apr-2020
• Refers: ASTM E1542-20 - Standard Terminology Relating to Occupational Health and Safety
• Effective Date: 01-Jan-2020
• Refers: ASTM E1542-18 - Standard Terminology Relating to Occupational Health and Safety
• Effective Date: 01-Feb-2018
• Refers: ASTM F1449-08(2015) - Standard Guide for Industrial Laundering of Flame, Thermal, and Arc Resistant Clothing
• Effective Date: 01-Jul-2015
• Refers: ASTM F1002-14 - Standard Performance Specification for Protective Clothing and Materials for Use by Workers Exposed to Specific Molten Substances and Related Thermal Hazards
• Effective Date: 01-Sep-2014
• Refers: ASTM F1002-13 - Standard Performance Specification for Protective Clothing and the Materials from Which It Is Made for Use by Workers Exposed to Specific Molten Substances and Related Thermal Hazards
• Effective Date: 01-Jul-2013
• Refers: ASTM E1542-10 - Standard Terminology Relating to Occupational Health and Safety
• Effective Date: 01-Aug-2010
• Refers: ASTM F1449-08 - Standard Guide for Industrial Laundering of Flame, Thermal, and Arc Resistant Clothing
• Effective Date: 15-Feb-2008
• Refers: ASTM F1002-06 - Standard Performance Specification for Protective Clothing for Use by Workers Exposed to Specific Molten Substances and Related Thermal Hazards
• Effective Date: 01-Feb-2006
• Refers: ASTM G88-05 - Standard Guide for Designing Systems for Oxygen Service
• Effective Date: 01-Jul-2005
• Refers: ASTM F1002-05 - Standard Performance Specification for Protective Clothing for Use by Workers Exposed to Specific Molten Substances and Related Thermal Hazards
• Effective Date: 01-Jan-2005
• Refers: ASTM E1542-93(2004) - Standard Terminology Relating to Occupational Health and Safety
• Effective Date: 01-Apr-2004
• Refers: ASTM F1449-92(2000)e1 - Standard Guide for Care and Maintenance of Flame, Thermally and Arc Resistant Clothing
• Effective Date: 10-Nov-2001
• Refers: ASTM F1449-01 - Standard Guide for Care and Maintenance of Flame, Thermally and Arc Resistant Clothing
• Effective Date: 10-Nov-2001

Overview

ASTM E2349-19: Standard Practice for Safety Requirements in Metal Casting Operations establishes comprehensive guidelines for the design, construction, and operation of machinery and equipment used in various metal casting processes. The standard focuses on sand preparation, molding, core making, melting, pouring, and the cleaning and finishing stages-excluding die casting operations. Developed by ASTM International, this practice is intended to minimize occupational injuries by improving equipment safety and promoting effective training for foundry personnel.

Compliance with ASTM E2349-19, in conjunction with regulations such as OSHA 29 CFR 1910, helps provide a relatively safe working environment and supports legal and ethical obligations for workplace safety in metal foundries.

Key Topics

• Scope of Application

  • Applicable to all new installations after the standard's publication.
  • Requires existing installations to conform as feasibly as practical.
  • Applies to equipment moved within or between facilities unless only relocated a short distance for minor adjustments.

• Personnel Safety and Training

  • Stresses the necessity of comprehensive training for both supervisors and employees.
  • Encourages the integration of industry-specific protective measures and personal protective equipment (PPE).

• Equipment Design and Construction

  • Calls for hazard reduction through design, safeguarding mechanisms, and warning signage in accordance with ANSI Z535 standards.
  • Addresses guarding of moving parts, hazard zone identification, and installation of emergency stop devices.

• Operational Procedures

  • Recommends documented procedures for installation, startup, shutdown, maintenance, and troubleshooting.
  • Emphasizes preventive maintenance, inspection frequency, and employee responsibilities.

• Hazard Control and Safeguarding

  • Covers the implementation of physical guards, presence-sensing devices, and lockout/tagout procedures (in line with OSHA requirements).
  • Includes requirements for guarding hazard zones, moving components, and installing protective devices where necessary.

Applications

ASTM E2349-19 provides value to a wide range of stakeholders in the metal casting industry, including:

• Foundries and Metal Casting Facilities

  • Implementation of standardized safety measures for sand preparation, molding, core making, melting, pouring, and finishing operations.
  • Application to new and existing machinery, ensuring ongoing safety compliance as equipment is installed, relocated, or retrofitted.

• Machinery and Equipment Manufacturers

  • Guidance for designing and constructing compliant metal casting equipment.
  • Required provision of clear operating instructions, identification plates, and maintenance guidelines.

• Plant Safety Managers and Supervisors

  • Framework for developing site-specific safety policies, hazard assessments, and employee safety training programs.

• Regulatory and Compliance Officers

  • Benchmark for measuring compliance with industry standards and relevant occupational safety regulations.

By adhering to ASTM E2349-19, organizations reduce the risk of injury, improve operational efficiency, and ensure regulatory compliance, supporting both workplace safety and productivity.

Related Standards

ASTM E2349-19 references and complements a variety of other standards to provide a holistic safety framework for metal casting operations, including:

• ASTM Standards

  • ASTM E1542: Terminology Relating to Occupational Health and Safety
  • ASTM F1002: Protective Clothing for Workers Exposed to Molten Substances

• ANSI/ASME Standards

  • ANSI/ASSP Z490.1: Safety, Health and Environmental Training
  • ANSI B15.1, B20.1: Guarding and Conveyors
  • ASME B30 Series: Cranes, Slings, and Lifting Devices

• NFPA Codes

  • NFPA 70: National Electrical Code
  • NFPA 86: Standard for Ovens and Furnaces

• OSHA Regulations (29 CFR 1910)

  • General Industry Safety, Lockout/Tagout, Confined Spaces, and PPE

• American Foundry Society (AFS) Guidelines

  • Personal Protective Equipment and Foundry Health Practices

Adopting ASTM E2349-19 as part of an integrated safety management system ensures alignment with internationally recognized best practices and regulatory requirements in metal casting operations.

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: E2349 − 19
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 E2349; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) 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
movementofheavyobjects,theuseoflargeovensandmeltfurnaces,andprocessingofhotmaterials.
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. This
practice is not intended to supersede or replace any applicable federal, state, or local governmental
safety regulations or requirements, but rather, it is intended to augment and support any such
requirements. Operating rules are not included in this practice unless they are vital to safety.
Compliancewiththispracticeshouldprovidearelativelysafeenvironment,whichisafundamental
requirement in preventing occupational injuries.
Contents
Introduction
1 Scope 8.2 Core Making
2 Referenced Documents 8.3 Molding Equipment
3 Terminology 8.4 Fuel-Fired Equipment
4 Materials and Manufacture 8.5 Operation Procedures for Sand Preparation, Molding, and Core Making
4.1 Responsibility 9 Melting and Pouring
4.2 Inherent Hazards 9.1 Cupola
4.3 Installation 9.2 Electric Furnaces – Induction Melting and Induction Holding
4.4 Power Requirements 9.3 Electric Furnaces – Direct Arc Furnaces
4.5 Electrical Ground Faults 9.4 Ladles
4.6 Fluid Power Off 9.5 Molten Metal Handling and Pouring Equipment
4.7 Electrical Equipment Grounding 9.6 Maintenance and Inspection
4.8 Fluid Exhaust (Gas or Liquid) 9.7 Molten Metal Treatment
5 Care of Equipment – General Provisions 9.8 Specific Material Handling Equipment
5.1 Instructions 9.9 Molten Metal Handling and Pouring
5.2 Installation 9.10 Overhead Handling of Molten Material
5.3 Inspection and Preventive Maintenance 10 Cleaning and Finishing
5.4 Maintenance Personnel Training and Experience 10.1 Care of Cleaning and Finishing Equipment
5.5 Startup Procedure 10.2 Specific Equipment Safeguards – Cleaning and Finishing
5.6 Shutdown Procedure 10.3 Abrasive Blasting
5.7 Troubleshooting, Maintenance, and Repair 10.4 Chipping
6 Safeguards – General Requirements 10.5 Abrasive Wheels
6.1 Responsibility for Safeguarding 10.6 Operating Procedures for Abrasive Wheels
6.2 Guarding 10.7 Portable Abrasive Wheels
6.3 Hazard Zone Guarding 10.8 Grinding Magnesium
6.4 Hazard Zone Protective Devices 10.9 Molten Salts Cleaning
7 Operation of Equipment – General Requirements 10.10 Hooks Designed for Handling Castings
7.1 Employer’s Responsibility 10.11 Slings
7.2 Employee’s Responsibility 10.12 Lighting
8 Sand Preparation, Molding, and Core Making 11 Keywords
8.1 Sand Handling and Preparation
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E2349 − 19
1. Scope ization established in the Decision on Principles for the
Development of International Standards, Guides and Recom-
1.1 This practice covers the requirements of applying the
mendations issued by the World Trade Organization Technical
design, construction, and operation of the machinery and
Barriers to Trade (TBT) Committee.
equipmentusedinmetalcastingoperations—sandpreparation,
molding and core making, melting and pouring, and cleaning
2. Referenced Documents
and finishing. This practice does not apply to die casting
2.1 ASTM Standards:
operations.
E1542Terminology Relating to Occupational Health and
1.2 Purpose—The requirements of this practice, including
Safety
the training of supervisors and employees, are intended to
F1002Performance Specification for Protective Clothing
minimizethepossibilityofinjurytooperatingandmaintenance
and Materials for Use by Workers Exposed to Specific
personnel while working on, or in the vicinity of, the specified
Molten Substances and Related Thermal Hazards
equipment. Compliance with this practice, in conjunction with
F1449Guide for Industrial Laundering of Flame, Thermal,
OSHA regulations, provides a relatively safe environment,
and Arc Resistant Clothing
which is a fundamental requisite in helping to prevent occu-
G88Guide for Designing Systems for Oxygen Service
pational injuries.
G128/G128MGuide for Control of Hazards and Risks in
1.3 Application:
Oxygen Enriched Systems
1.3.1 New Installations—After the date of publication, all
2.2 ANSI Standards:
new installations within the scope of this specification shall be
ANSI/ASSP A1264.1Safety Requirements for Workplace
in conformance with its requirements. Any existing machine Walking/Working Surfaces and TheirAccess; Workplace,
installation moved to a new plant or another location in the
Floor, Wall, and Roof Openings; Stairs and Guardrail/
same plant is deemed a new installation when it is installed in Handrail Systems
the new location. However, an existing installed machine
ANSI B7.1Safety Requirements for the Use, Care and
(former installation) that is moved for a short distance, for Protection of Abrasive Wheels.
example, to provide additional aisle space, is not deemed to be
ANSI B11.6Safety Requirements for Manual Turning Ma-
a new installation. chines with or without Automatic Control
1.3.2 Existing Installations—After the approval date of this
ANSI B11.9Safety Requirements for Grinding Machines
practice, installations existing on, or before, this date shall be ANSI B11.TR3Risk Assessment and Risk Reduction—A
modified as necessary to be in conformance with all require-
GuidetoEstimate,EvaluateandReduceRisksAssociated
ments of this practice. Where it is not practical to modify an with Machine Tools
existing facility in conformance with this practice, deficiencies
ANSI B15.1Mechanical Power Transmission Apparatus
shall be noted and plans for compliance shall be included in ANSI/ASSP Z9.2Fundamentals Governing the Design and
any future facility or equipment changes. Those facilities and
Operation of Local Exhaust Ventilation Systems
equipment on order or in the process of construction on the ANSI/ASSPZ9.4VentilationandSafePracticesofAbrasive
date of publication of this practice shall be considered as an
Blasting Operations
existing installation. This practice applies to existing equip-
ANSI/ASSP Z244.1Control of Hazardous Energy Lockout,
ment if it lacks the necessary employee protection (personal
Tagout, and Alternative Methods
protective equipment or administrative controls).
ANSI/ASSP Z359Fall Protection
ANSI/ASSP Z490.1 Criteria for Accepted Practices in
1.4 The values stated in inch/pound units are to be regarded
Safety, Health and Environmental Training
asthestandard.Thevaluesinbracketsareforinformationonly.
ANSI Z535.1Safety Color Code
1.5 The text of this practice references notes and footnotes
ANSI Z535.2Environmental and Facility Safety Signs
whichprovideexplanatorymaterial.Thesenotesandfootnotes
ANSI Z535.3Criteria for Safety Symbols
(excluding those in tables and figures) shall not be considered
ANSI Z535.4Product Safety Signs and Labels
as requirements of the standard.
ANSI Z535.5Accident Prevention Tags
1.6 This standard does not purport to address all of the
2.3 ASME Standards:
safety concerns, if any, associated with its use. It is the
ASME B5.35Machine Mounting for Abrasive Discs and
responsibility of the user of this standard to establish appro-
Plate-Mounted Wheels
priate safety, health, and environmental practices and deter-
ASME B107.4Driving & Spindle Ends for Portable Hand,
mine the applicability of regulatory limitations prior to use.
Air and Electric Tools (Percussion Tools Excluded)
1.7 This international standard was developed in accor-
dance with internationally recognized principles on standard-
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
This practice is under the jurisdiction of ASTM Committee E34 on Occupa- the ASTM website.
tionalHealthandSafetyandisthedirectresponsibilityofSubcommitteeE34.10on Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
Industrial Safety. 4th Floor, New York, NY 10036, http://www.ansi.org.
Current edition approved March 1, 2019. Published March 2019. Originally Available from American Society of Mechanical Engineers (ASME), ASME
approved in 2005. Last previous edition approved in 2018 as E2349–18. DOI: International Headquarters, Two Park Ave., New York, NY 10016-5990, http://
10.1520/E2349-19. www.asme.org.
E2349 − 19
ASME B20.1Safety Standard for Conveyors and Related OSHA Instruction STD 1-12.8 October 30, 1978 (Program
Equipment (ASME B20.1) Directive#100-39)Subject:29CFR1910.215(a)(4)Abra-
ASME B30.2Overhead and Gantry Cranes (Top Running, sive Wheel Machinery—Work Rests
Bridge, Single or Multiple Girder Top Running Trolley
NOTE 1—State plan states may have their own regulations.
Hoist)
2.9 American Foundry Society (AFS):
ASME B30.5Safety Code for Crawler, Locomotive, and
Guide for Selection and Use of Personal Protective Equip-
Truck Cranes
ment and Special Clothing for Foundry Operations Man-
ASME B30.9Slings
aging the Foundry Indoor Air Environment
ASME B30.10Hooks
Foundry Health and Safety Guides
ASME B30.11Monorails and Underhung Cranes
ASME B30.20Below-the-Hook Lifting Devices
3. Terminology
2.4 CGA Standard:
3.1 For definitions of terms used in this standard, see
CGA G-4.4Industrial Practices for Gaseous Oxygen Trans-
Terminology E1542.
mission and Distribution Piping Systems
3.2 Definitions:
2.5 IAPMO Document:
3.2.1 adjustable barrier guard, n—physical barrier with
Uniform Plumbing Code
adjustablesectionsthatisdesignedtoprevententryofanypart
2.6 IES Document:
of the body into the hazard zone by reaching through, over,
Lighting Handbook
under, or around the barrier.
2.7 NFPA Standards:
3.2.2 arc furnace, n—see direct arc furnaceand indirect arc
NFPA 49Fire Protection Guide to Hazardous Materials
furnace.
NFPA 53Recommended Practice on Materials, Equipment
3.2.3 bail/spreader, n—hoop or arched connection between
and Systems Used in Oxygen-Enriched Atmospheres
the crane hook and ladle or between crane hook and ladle
NFPA 55Compressed Gases and Cryogenic Fluids Code
trunnions.
NFPA 68Guide for Venting of Deflagrations
3.2.4 blast, n—in foundry operations, air or oxygen-
NFPA 70National Electrical Code
enriched air that is blown, under pressure, into a cupola for
NFPA 70EStandard for Electrical Safety in the Workplace
supporting combustion.
(Includes Arc-Flash)
NFPA 79Electrical Standard for Industrial Machinery
3.2.5 blast compartment, n—that portion of the blasting
NFPA 86Standard for Ovens and Furnaces
enclosure that contains the blasting media propulsion device.
NFPA 91Standard for the Installation of Blower and Ex-
3.2.6 blow plate, n—plate affixed to the magazine or blow
haust Systems
headofacore-ormold-blowingmachinehavingholesorslots
NFPA480StandardforStorageandHandlingofMagnesium
through which sand or other media in the magazine or blow
NFPA 484Standard for Combustible Metals
head passes into the core or mold cavity or around the pattern
2.8 Occupational Safety and Health Administration:
when air or other gas pressure is applied to the machine.
29 CFR 1910Code of Federal Regulations, Part 1910
3.2.7 bottom discharge (pour, tap) ladle, n—ladle that has
General Industry
itsmoltenmetalcontentsdischargedthroughanopeninginthe
29 CFR 1910.23Walking-Working Surfaces
bottom.
29 CFR 1910.94(a)Ventilation—Abrasive Blasting
3.2.8 channel furnace, n—electric induction furnace in
29 CFR 1910.145 Specification for Accident Prevention
which heat is electrically induced in the metal in a refractory
Signs and Tags
channel.
29 CFR 1910.146Permit-Required Confined Spaces
29 CFR 1910.147Control of Hazardous Energy (Lockout/
3.2.9 charge, n—in foundry operations, material introduced
Tagout) into a melting furnace for the production of molten metal.
29 CFR 1910.184Slings
3.2.10 core, n—in foundry operations, preformed aggregate
29 CFR 1910.215Abrasive Wheel Machinery
or collapsible insert placed in a mold to shape the interior or
29 CFR 1910.217Mechanical Power Presses
that part of a casting that cannot be shaped by the pattern.
29CFR1910.331–335ElectricalSafety-RelatedWorkPrac-
3.2.11 core binder(s), n—any material, liquid or solid,
tices
which is used to bond core aggregates.
3.2.12 corebox, n—a (wood, metal, or plastic) structure, the
Available from Compressed Gas Association (CGA), 14501 George Carter cavity of which has the shape of the desired core that is to be
Way, Suite 103, Chantilly, VA 20151, http://www.cganet.com.
made therein.
Available from International Association of Plumbing and Mechanical
3.2.13 coreless furnace, n—electric induction furnace con-
Officials, 4755 E. Philadelphia St., Ontario, CA 91761, http://www.iapmo.org.
Available from Illuminating Engineering Society (IES), 120 Wall Street, New
sistingofaninductioncoilsurroundingacrucibleorrefractory
York, NY 10005-4001, http://www.ies.org.
lining in which metal is melted or molten metal is retained.
Available from National Fire Protection Association (NFPA), 1 Batterymarch
Park, Quincy, MA 02169-7471, http://www.nfpa.org.
9 10
Available from Occupational Safety and Health Administration (OSHA), 200 Available from the American Foundry Society, 1695 N. Penny Lane,
ConstitutionAve., NW, Washington, DC 20210, http://www.osha.gov. Schaumburg, IL 60173.
E2349 − 19
3.2.14 core- or mold-blowing or shooting machine, 3.2.33 lip, n—in foundry operations, formed “U” or “V”
n—machine for injecting sand or other media into the core or depression in a molten metal outlet to confine the stream.
mold cavity by means of compressed air or other gas.
3.2.34 main burner, n—primary combustion device com-
3.2.15 crane ladle, n—ladle handled by an overhead crane.
monly ignited by a secondary source.
3.2.16 crucible, n—in foundry operations, container used
3.2.35 mold, n—in foundry operations, form that contains
for the melting, holding, and pouring of metal.
the cavity into which molten metal is poured to produce a
casting of definite shape and outline.
3.2.17 cupola, n—in foundry operations, vertical shaft-type
furnace for melting and/or producing molten metal by com-
3.2.36 molding machine, n—mechanical device for com-
busting coke or other fuels using a blast, and possibly addi-
pactingmoldingmedia(usuallysand)aboutthepattern(s),thus
tional pure oxygen, that is introduced through the cupola
forming the mold.
tuyeres.
3.2.37 moving frame, n—thatpartofamoldingmachinethat
3.2.18 cupola drop, n—materialsdroppedfromthecupolaat
supports the flask and imparts the motions necessary to the
the end of a heat.
mold making process.
3.2.19 direct arc furnace, n—furnace in which heat is
3.2.38 muller, n—machine that blends, coats, kneads, or
produced by an electric arc between electrodes and the charge.
mechanicallycombinesvarioussand(s)orothermediausedfor
foundry purposes with binders and other additive agents.
3.2.20 drop area, n—in foundry operations,theareadirectly
under the cupola that receives the hot bed coke or other hot 3.2.38.1 Discussion—Typically, it consists of a circular
materialsfromtheinsideofthefurnacewhenthebottomdoors
container in which rotating plows or mill wheels (mullers), or
or side access door are opened. both, are mounted.
3.2.21 drop zone, n—the zone adjacent to the drop area that
3.2.39 pattern, n—in foundry operations, form of wood,
is exposed to drop hazards during the dropping process.
metal, or other material against which molding material is
compacted to make a mold for casting metals.
3.2.22 dross, n—metaloxidesorforeignmatter,orboth,that
accumulates on the surface of nonferrous molten metal.
3.2.40 pouring, n—in foundry operations, final transfer of
molten metal before its solidification into its intended form.
3.2.23 finishing, v—in foundry operations, attainment of a
desiredsurfacefinishorfinishcharacteristicsbysuchmeansas
3.2.41 pouring area, n—locationinafoundrywheremolten
abrasive impingement, grinding, or polishing.
metal is poured into molds or transferred from a ladle to a
furnace.
3.2.24 flask, n—in foundry operations, container, without
top or bottom, used to contain the sand or other media while it
3.2.42 qualified engineer, n—one who possesses an engi-
isbeingformed.Itismadeintwoormoreparts,thelowerpart
neeringdegreefromanaccreditedinstitutionofhigherlearning
calledthedragandtheupperpartcalledthecope.Intermediate
or a certificate of professional standing and has engineering
sections, if any, are called cheeks.
experience with the kind of work and equipment involved.
3.2.25 flask lifting device, n—chains, rods, bails, cables,
3.2.43 qualified person, n—individual determined by the
slings,andothermaterialsusedtosupportaloadsuchasaflask
employer to have the training and experience to safely operate
for turning, inverting, or transporting.
or maintain the equipment involved.
3.2.26 gas handling system, n—the collective group of
3.2.44 reactive metal, n—any metallic element or alloy that
equipment that draws cupola gas from the furnace.
is readily oxidized with the release of large quantities of heat.
3.2.27 heat, n—in foundry operations, stated weight of
3.2.45 runout pit, n—chamber placed below or in front of a
metal obtained from a period of melting in a cupola or furnace
furnace, or both, to receive molten material in an emergency.
or the time required to melt and process this material.
3.2.46 sand mixer, n—machine for conditioning mold and
3.2.28 indirect arc furnace, n—furnace in which heat is
core sand by controlled mixing with additives.
produced by an electric arc between electrodes.
3.2.47 sand muller, n—machine for conditioning mold and
3.2.29 induction furnace—see channel furnace and coreless
core sand by controlled mixing with additives.
furnace.
3.2.48 sand system, n—that part of a foundry installation
3.2.30 ladle handler, n—mechanism used to suspend,
thatprocessesandtransportssandorothermediainbulkform.
transport, raise and/or lower a ladle.
3.2.49 screen (sand), n—sieve or riddle with openings of
3.2.31 ladle pouring stand, n—structuraldeviceforsupport-
definite size used to separate one grain size from another or to
ing or tilting a ladle, or both.
remove lumps and foreign objects from sand.
3.2.32 lance, oxygen, n—device consisting of steel pipe,
3.2.50 skimming, n—in foundry operations, removing slag
tubing, oxygen source, and controls.
or dross from the surface of the molten metal.
3.2.32.1 Discussion—Frequently used to open frozen tap or
slag holes; also occasionally to oxidize impurities in molten 3.2.51 skip hoist, n—basket, bucket, or other container that
metal bath. is drawn or elevated on rails by a pulling or pushing action.
E2349 − 19
3.2.52 slag, n—nonmetallic byproducts and contaminants tached to the machine or equipment adjacent to the manufac-
generated during the melting, transferring, and holding of turer’s original identification plate (see 4.1.5). The new
molten metal. identification plate shall state the date the modification(s) was
made and the person or organization responsible. (Restrictions
3.2.53 slagging, v—see skimming.
onmodificationsoralterationsarenotintendedtobarrepairor
3.2.54 slag hole or door, n—opening in the furnace through
maintenance,includingthesubstitutionofsubstantiallyequiva-
which slag is removed.
lent components.)
3.2.55 slinger, n—machine that throws sand or other media
4.2 Inherent Hazards:
into a flask, corebox, or other container.
4.2.1 Hazards to Personnel Associated With Moving
3.2.56 tapping, v—in foundry operations, removing molten
Parts—Hazards to personnel associated with moving parts
material from the furnace by opening a tap hole.
(other than point of operation hazards) shall be guarded in
3.2.57 transfer car, n—in foundry operations, vehicle used
accordance withANSI B15.1 orASME B20.1, as appropriate.
for transporting vessels or material(s), usually in a fixed path.
NOTE 2—Some examples of hazards to personnel associated with
3.2.58 trunnions, n—shafts used to support, turn, or tilt a
moving parts are:
vessel.
(1)Rotating components, such as flywheels, gears, sheaves, and shafts
in proximity to personnel;
3.2.59 tumbling barrel, n—power-driven rotating drum or
(2)Run-in pinch points, such as meshing gears, belts, and chains; and
barrel in which castings are cleaned or polished, or both. The
(3)Pinch points between the moving and stationary components of the
castings act as abrasives for each other or are tumbled in an
machine.
abrasive media.
4.2.1.1 Responsibility – Manufacturer—The manufacturer
3.2.60 tuyere, n—nozzle opening through which the blast
shall endeavor to eliminate the hazards by design or provide
enters a cupola.
protectionagainstthem.Whenhazardscannotbeeliminatedby
design or protection, the manufacturer shall warn against them
4. Materials and Manufacture
byusingsignsinaccordancewithANSIZ535.1,ANSIZ535.2,
ANSIZ535.3,ANSIZ535.4,andANSIZ535.5,asappropriate.
4.1 Responsibility—It shall be the responsibility of any
person purchasing, constructing, reconstructing, or modifying
NOTE 3—Together, these five ANSI standards contain information
any equipment covered by this practice to:
needed to specify formats, colors, and symbols for safety signs used in
4.1.1 Design, construct, and modify equipment in accor-
environmentalandfacilityapplications,productapplications,andaccident
dance with the provisions of this practice. (Consider other prevention signs.
applicable safety standards.)
4.2.1.2 Responsibility – Employer—Equipment with mov-
4.1.2 Select and include in construction only components
ing parts that could cause injuries to personnel shall be
thathaveaworkingratingequaltoorgreaterthanthatrequired
guarded.
to meet the maximum recommended operating condition(s).
4.2.2 Hazards to Personnel Associated With the Point of
4.1.3 Furnish printed instructions with each unit of equip-
Operation—Refer to Section 6.
ment. (To minimize hazards, it is essential that this material be
4.2.3 Hazards to Personnel Associated With Broken,
readily available to maintenance, operations, and engineering
Falling, or Flying Equipment Components—The manufacturer
personnel.) The instructions shall include:
shalldesign,secure,orcovermachinecomponentstominimize
4.1.3.1 Engineering drawings and other materials required
hazards caused by falling or flying components resulting from
to install and place such equipment into operation properly.
loosening or breakage.
4.1.3.2 Operating and maintenance instructions as specified
in Section 5.
4.3 Installation:
4.1.3.3 Spare parts lists.
4.3.1 Employer Responsibility—The employer shall be re-
4.1.3.4 Procedures in accordance with hazardous energy
sponsible for safe conditions for installing the equipment
control (6.5) standard shall be followed.
covered by this practice.
4.1.4 Hazard alert signs, when used, shall comply with the
4.3.2 Safeguarding During Construction, Reconstruction,
following standards: ANSI Z535.1, ANSI Z535.2, ANSI
or Modification—Use of barriers, shields, and covers over
Z535.3, ANSI Z535.4, and ANSI Z535.5.
excavations, pits, or tanks shall be required and used. Means
4.1.5 Apply a legible identification plate to each piece of
shall be provided to prevent unauthorized persons from enter-
equipment. This plate shall include, as a minimum, the
ing an area or zone in which construction or repair is in
manufacturer’s name, equipment type or model identification,
progress.
or both, serial number, and rated capacity(s).
NOTE 4—ANSI/ASSP A1264.1 contains the appropriate requirements
4.1.6 Ensure that any modification(s) or alteration(s) to a
and recommendations.
piece of equipment or machinery covered by this practice that
result in a change from the manufacturer’s original design or 4.3.3 Workstation—Each workstation shall have space to
intended method of operation, or both, shall be done under the permit work without physical interference from equipment or
supervision of a qualified engineer and shall comply with another employee(s) within that workstation. Services, includ-
mandatory safety standards for that given category of equip- ing electric power, air hydraulic, water, steam, or process
ment. An additional legible identification plate shall be at- liquids, shall be delivered in identified conductors with shutoff
E2349 − 19
valves or disconnecting means legibly marked, and shall be 4.4.2.5 While power has been disconnected when the door
visible and accessible. isopened,electricalpowerremainsattheprimaryterminals.In
addition, in some instances capacitors will remain charged and
4.4 Power Requirements:
must be discharged to remove all voltage from the circuits
4.4.1 Disconnect Means—All motors, motor circuits, and
inside the cabinet.
controllers shall have disconnecting means as required by
NOTE 5—Considerations for arc flash should be taken into account
Article 430 of the National Electric Code (NFPA 70). The
(NFPA 70E).
disconnecting means shall be capable of being locked in the
4.4.3 Fluid Power Off—Means shall be provided for isolat-
(OFF) position.
ing fluid (air, oil, or other) energy sources from a machine, or
4.4.1.1 Disconnect Means Identification—Each disconnect
group of machines, controlled as a system. These means shall
means shall be marked with a legible, durable label that
have provisions for being locked in the isolating mode.
identifies the voltage and equipment controlled. Identification
Pressure buildup on the machine side port of the isolating
shall be verified at time of installation.
meansshallbeeliminatedbypositivemeanssuchasventingto
4.4.1.2 Disconnection:
atmosphere or drainage to tank.
(1)Control circuits shall be so arranged that they will be
4.5 Electrical Ground Faults:
disconnected from all sources of power when disconnecting
4.5.1 Grounded Control Circuit—When one side of the
means is in the open (OFF) position.
controlcircuitisgrounded,thecontrolcircuitshallbedesigned
(2)There shall be an interlock, on separate power source
sothatanaccidentalgroundwillnotstartamotor,energizeany
feeds, that opens when the main disconnect is opened.
component, or cause a machine movement.
(3)The disconnecting means consists of two or more
separate devices, one of which disconnects the motor and the
NOTE 6—Circuits that have all coils or solenoid(s) common to the
controller from the source(s) of power supply for the motor, grounded side of the control circuit, without intervening contacts, will
almost always meet these requirements on a circuit that is grounded. It is
and the other disconnects the control circuit(s) from its power
possible that circuits that do not have this characteristic are hazardous in
source. Where separate devices are used, they shall be located
that an accidental ground might cause unwarranted energization or
immediately adjacent, one to the other.
machine movement, or both.
4.4.1.3 Disconnection Hazards—Where the operation of a
4.5.2 Ungrounded Control Circuit—Ungrounded control
disconnecting means could create a hazard, a suitable hazard
circuits shall have operative ground-indicating lights. An
alertingnameplateshallbeprovidedandlocatedadjacenttothe
indicatedgroundshallbereportedatoncebytheemployeeand
label required in 4.4.1.1
investigated immediately. If a personnel hazard exists, correc-
4.4.1.4 Motor-Starting Equipment—Motor-starting equip- tions shall be made before resuming operation of the equip-
mentwiththepotentialtorestartamotorautomaticallyafteran ment.
unplanned power interruption or power outage shall not be
NOTE 7—Without grounds, each light has only one half voltage and
used when automatic restarting would potentially result in
both lights are therefore equally dim—the normal condition. A ground
injury to personnel. It shall be necessary to restart the motor
causes one light to glow brightly, the other to dim or go out. Depending
uponthelocationoftheaccidentalground,thisindicationisusuallyeither
manually.
constant or intermittent during operations. In an ungrounded system, it is
4.4.2 Electrical Power Off – Electrical Panels or Electrical
not clear whether the first accidental ground will indicate a personnel
Furnaces: hazard possible with the second accidental ground—or with simultaneous
double accidental grounding. For instance, a ground on the common coil
4.4.2.1 Disconnect Means—All control and power circuits
side of the control circuit will, in effect, merely convert the ungrounded
shall be equipped with disconnecting means that have the
circuit into a grounded circuit. The remarks in 4.5.1 and Note 6 are then
capability to be locked in the open (OFF) position for the applicable. However, where the first accidental ground is on the contact
side, it could possibly create a personnel hazard. This potential hazard
protection of the operating or maintenance personnel.
must be resolved by authorized personnel.
4.4.2.2 Isolation (Disconnect) Switches—Isolation switches
4.6 Fluid Power Off—Means shall be provided for isolating
not capable of interrupting load current shall not be opened
fluid (air, oil, or other) energy sources from a machine, or
under load and shall be provided with signage warning against
group of machines, controlled as a system. These means shall
opening under load.
have provisions for being locked in the isolating mode.
4.4.2.3 Wherepossible,theseisolationswitchesshallbekey
Pressure buildup on the machine side port of the isolating
interlocked with the circuit-interrupting device so that the
meansshallbeeliminatedbypositivemeanssuchasventingto
isolation switch cannot be opened under load. Individual
atmosphere or drainage to tank.
consideration shall be given to keep these switches in a locked
4.7 Electrical Equipment Grounding—All electrical equip-
closed (ON) condition during normal operation.
ment shall be grounded in accordance with the National
4.4.2.4 Door Interlock—All doors providing access to elec-
Electrical Code.
trical circuits that operate at over 50 V shall be interlocked to
disconnect electrical power when the door is opened. If
4.8 Fluid Exhaust (Gas or Liquid)—The employer shall be
voltages in excess of 50 V remain after electrical power has
responsible for arranging conductors to direct the exhaust of
been disconnected, hazard alert signs shall be provided. fluidstoalocation(s)thatwillnotcreateahazardouscondition.
E2349 − 19
5. Care of Equipment – General Provisions 5.6 Shutdown Procedure:
5.6.1 Manufacturer—The manufacturer shall recommend a
5.1 Instructions:
shutdown procedure that minimizes hazards.
5.1.1 Manufacturer—The manufacturer shall furnish oper-
5.6.2 Employer—The employer shall establish and follow a
ating and maintenance instructions with equipment covered by
shutdown procedure considering the manufacturer’s recom-
this practice. These shall be in conformance with hazardous
mendations for necessary lockouts before allowing any
energy control (6.5).
inspection, adjustments, or maintenance of the equipment
NOTE 8—Most operating and maintenance manuals provide specific
covered by this practice.
instructions to aid in the proper operation and maintenance of the
5.6.3 Employee—The employee shall follow shutdown,
equipment. Optional means to provide adequate instructions include
lockout, and safeguarding procedures established by the em-
written, illustrated, audio, and visual recorded material. However, the
ployer.
employer is responsible for making sure all equipment is adequately
guarded and safe for operation.
5.7 Troubleshooting, Maintenance, and Repair:
5.7.1 Employer—The employer shall provide training for
5.1.2 Modification/Reconstruction—Any person modifying
employees engaged in troubleshooting, maintenance, or repair
or reconstructing any piece of equipment covered by this
in isolated or hidden areas. For work in confined spaces, entry
practice shall furnish operating and maintenance instructions,
procedures shall be in conformance with 29 CFR 1910.146.
including updated functional engineering drawings of controls
5.7.2 Employee—The employee shall use the monitoring
covering the modified portion of the equipment. Refer to
means established by the employer to inform others of his or
Section 4.
her presence when performing maintenance or setup work in
NOTE9—Manymodificationandrebuildingeffortsaresoextensivethat
hidden or isolated areas.
the original instructions from the manufacturer are incorrect or meaning-
5.7.3 Physical Entry Into Machine or Equipment—The
less.
employee shall follow established lockout/tagout and confined
5.1.3 Employer—The employer shall specify corrective
spaceproceduresforthemachineorequipmentbeforephysical
maintenance procedures for the equipment covered by this
entry.
practice that minimize hazards to operating and maintenance
NOTE 10—It is possible that the rules for confined space or permit-
personnel.
required confined space, or both, will also apply.
5.2 Installation—The employer shall provide work areas
5.7.4 Troubleshooting, Maintenance, and Repair With
around the equipment covered by this practice to minimize
Power On—Exception for qualified persons only: When nec-
hazards to operating and maintenance personnel.
essary to locate and define problems and make adjustments
5.3 Inspection and Preventive Maintenance—The employer
with power on, qualified persons are allowed to perform work
shall establish and supervise a program of documented inspec-
onmachinesorequipmentwithguardsremovedorwithinareas
tionsandpreventivemaintenanceoftheequipmentcoveredby
protectedbybarriers,ifprotectivemeasureshavebeentakento
this practice. Designated personnel shall perform the required
train and supervise the employees to not place any part of the
inspections and maintenance.
body in the path of any movable machine or equipment
5.3.1 Thefrequencyofinspectingtheequipmentisbasedon
member or in contact with any hazardous energized electrical
the manufacturer’s recommendations, the number of hours
equipment.EmployeesshallfollowOSHAregulations29CFR
used per month, the maintenance history, and regulatory
1910.331, 29 CFR 1910.332, 29 CFR 1910.333, 29 CFR
requirements.Theemployershallschedulefrequentorperiodic
1910.334, and 29 CFR 1910.335.
inspections, or both, that would reveal hazards caused by age,
5.7.5 Defeating Protective Devices—No employee other
overloading, corrosion, fatigue, improper use, or improper
than authorized and qualified personnel performing special
installation.
maintenanceshallremove,bypass,oralteranydevicethatwas
provided to reduce hazardous conditions.
5.4 Maintenance Personnel Training and Experience—The
5.7.5.1 This practice does not condone defeating any pro-
employer shall provide trained and competent personnel for
tective device at any time. This practice does, however,
maintaining the equipment covered by this practice.
recognize that maintenance conditions exist when authorized
5.4.1 Competentmaintenancepersonnelshallhavethetech-
maintenance personnel would be permitted to bypass the
nical background necessary to understand the information
protectivedevice.Undersuchconditions,5.7.4shallbestrictly
containedinthemaintenancemanualsforthemachinetheyare
followed.
inspecting or maintaining.
5.7.6 Returning Equipment to Production—The employee
5.5 Startup Procedures:
shall verify that the machine or equipment has all guards
5.5.1 Manufacturer—The manufacturer shall recommend a
secured in place and operators have been informed before
startup procedure that minimizes hazards.
releasing it for production use.
5.5.2 Employer—The employer shall establish and follow a
6. Safeguards – General Requirements
startup procedure considering the manufacturer’s recommen-
dationsbeforeanyequipmentcoveredbythispracticeisplaced 6.1 Responsibility for Safeguarding:
in regular operation.
NOTE 11—It must be understood that in the application of this practice,
5.5.3 Employee—The employee shall follow the startup
there are responsibilities incumbent upon the employer, the manufacturer,
procedure established by the employer. the installer, and the operator of foundry equipment. (See ANSI B11.6,
E2349 − 19
ANSIB11.9,andANSIB11.TR3onhazardanalysisandriskassessment.)
6.3.1.2 It shall be in conformance with the maximum
Some safety features are incorporated in the design of the equipment.
permissible openings shown in Table 1.
Some protection depends on installation after assembly of the associated
6.3.1.3 It shall not create pinch points.
components in the field. Some safety features are a part of a building or
structureandarenotanintegralpartofthecomponentsthemselves.Some
6.3.1.4 It shall not be readily removable.
protectiondependsontheoperationandmaintenancebytheemployerand
6.3.1.5 It shall offer maximum visibility of the equipment
operators. Some protection depends on training and supervision.
operation consistent with the other requirements.
6.1.1 Manufacturer—The manufacturer of equipment shall
6.3.1.6 It shall be inspected at intervals as outlined inANSI
furnish equipment that is safe for the intended use as indicated
B11.6 and ANSI B11.9 standards.
by the employer.
6.3.2 Barrier Guard(s)—Barrier guards shall meet the fol-
6.1.2 Employer—The employer shall be responsible for the
lowing criteria:
installation and maintenance of guards, shields, or barriers and
for maintaining the condition and position of such devices to 6.3.2.1 Prevent bodily entry into the process pinch or shear
point by reaching through, over, under, or around the guard
protectagainstrecognizedhazardousconditions.Theemployer
shall be responsible for providing, installing, and maintaining during the production cycle;
any additional guards required to provide protection against
6.3.2.2 Conformance with the maximum permissible open-
recognized hazardous conditions created by the use or
ings shown in Table 1;
installation, or both, of the equipment.
6.3.2.3 Initselfcreatenopinchpointbetweentheguardand
6.2 Guarding—Potential hazards including, but not limited moving machine parts;
to, nip, pinch, shear, puncture, catching points, or a combina-
6.3.2.4 Use fasteners not readily removable by the operator
tion thereof shall be guarded.
so as to minimize the possibility of misuse or removal of
6.2.1 The guard openings shall be in conformance with
essential parts;
Table 1.
6.3.2.5 Be readily inspected for its effectiveness;
6.2.1.1 Manual operation, such as placing copes on drags,
6.3.2.6 Offer maximum visibility of the hazard zone consis-
manually closing molds, with or without mechanical assists,
tent with the other requirements; and
shall be excluded from mandatory guarding where variable
6.3.2.7 Be free of sharp edges, burrs, and so forth, which
conditions preclude the use of barriers or devices. For these
could be a hazard.
operations,specialemphasisshallbegiventooperatortraining.
6.3.3 Fixed Barrier Guards—A fixed barrier guard, when
6.2.1.2 Guarding by Location—Hazards that are inacces-
used, shall meet the criteria of 6.3.1.1 – 6.3.1.6 and shall be
sible due to height or distance shall be considered to be
attached securely.
guarded by location or position. However, when work is
performed in the vicinity of the hazard, either guarding or
NOTE 13—Addition of an interlock to a fixed barrier guard does not
hazardous energy control (6.5) applies.
necessarily make this an interlocked barrier guard.
6.3 Hazard Zone Guarding:
6.3.4 Interlocked Barrier Guards—An interlocked barrier
NOTE 12—Refers to guarding within that area of the operator’s work guard, when used, shall meet the requirements of 6.3.1.1 –
zone where the work process is being performed.
6.3.1.6 and shall be interlocked with the machine power or
controls so that the machine will not operate unless the hinged
6.3.1 Hazard Zone Guard(s)—Every hazard zone guard
or movable section of the guard is in the closed position(s).
shall meet the following design, construction, application, and
adjustment requirements:
6.3.4.1 If the interlock device is used as an alternative
6.3.1.1 Itshallprevententryofanypartofthebodyintothe measure for hazardous energy control (6.5), an authorized
hazard zone by reaching through, over, under, or around the
employee shall inspect the interlock device at the beginning of
guard. each shift of operation and immediately report any damage or
malfunction of the device to the supervisor. If an interlocking
device is found to be defective, the machine shall not be put
into operation until repaired and re-checked.
TABLE 1 Accepted Safe Opening Between Guard and Hazard
A
Zone
NOTE 14—The hinged or removable section(s) of this guard are
Distance of Opening from
Maximum Width of Opening
intended for use when frequent access is required.
Hazard Zone
B B
(in.) (mm) (in.) (mm)
6.3.5 Adjustable Barrier Guards—An adjustable barrier
1 1 1
⁄2 –1 ⁄2 13–38 ⁄4 6
1 1 3
guard shall be securely attached and shall meet the criteria of
1 ⁄2 –2 ⁄2 38–64 ⁄8 10
1 1 1
2 ⁄2 –3 ⁄2 64–89 ⁄2 13
6.3.1.1 – 6.3.1.6.
1 1 5
3 ⁄2 –5 ⁄2 89–138 ⁄8 16
1 1 3 6.3.5.1 This type of guard requires close supervision of use
5 ⁄2 –6 ⁄2 138–165 ⁄4 19
1 1 7
6 ⁄2 –7 ⁄2 165–191 ⁄8 22
and adjustment, or inadequate protection could result. It shall
1 1 1
7 ⁄2 –12 ⁄2 191–318 1 ⁄4 32
be the responsibility of the employer to establish and follow a
1 1 1
12 ⁄2 –15 ⁄2 318–394 1 ⁄2 38
1 1 7
program of periodic and regular inspection of power press and
15 ⁄2 –17 ⁄2 394–445 1 ⁄8 48
1 1 1
17 ⁄2 –31 ⁄2 445–800 2 ⁄8 54
auxiliary equipment. Refer to 29 CFR 1910.217(e).
A
Source: 29 CFR 1910.217 Table O-10.
B
NOTE 15—The adjustable sections allow different jobs to be run on the
Approximate.
equipment.
E2349 − 19
6.3.6 Hazard Warning—Where it is not feasible to guard 6.4.7.1 Two-Hand-Maintained Initiators—A two-hand-
against the hazard, or where the guard itself creates a hazard, maintainedinitiatorshallbedesigned,installed,andconnected
thepotentialhazardshallbemarkedprominentlytowarnofits to protect the operator by requiring application of both of the
existence. operator’s hands to the machine operating initiators until the
hazardous portion of the cycle is completed and shall be
6.4 Hazard Zone Protective Devices—Ahazard zone device
equipped with anti-tiedown features. Each hand control shall
shallbeprovidedtoprotecttheoperatorandotherpersonnelin
be protected against unintended activation and arranged by
the area by:
design, construction, or separation, or a combination of the
6.4.1 Preventing or stopping the equipment motion or con-
three, so that the concurrent use of both hands is required to
dition that would create a hazard or pinch point if any portion
initiate the equipment.
of the body is in the hazard zone;
6.4.7.2 Two-Hand Momentary Initiators—A two-hand mo-
6.4.2 Preventingpersonnelfrominadvertentlyreachinginto
mentaryinitiatorshallprotecttheoperatorbyrequiringthatthe
the hazardous motion that has started or been initiated;
single-cycle initiators be operated at a position so that the
6.4.3 Requiring personnel to position all parts of the body
operator cannot reach into the hazard zone during the hazard-
away from possible hazardous conditions and position both
ous portion of the cycle. Two-hand momentary initiators shall
hands on initiators during the period of time when the
beequippedwithanti-tiedownfeature.Eachhandcontrolshall
possibility of pinching motions or hazardous conditions is
be protected against unintended activation and arranged b
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: E2349 − 18 E2349 − 19
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 E2349; 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 (´) 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. This
practice is not intended to supersede or replace any applicable federal, state, or local governmental
safety regulations or requirements, but rather, it is intended to augment and support any such
requirements. 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
1 Scope 8.2 Core Making
2 Referenced Documents 8.3 Molding Equipment
3 Terminology 8.4 Fuel-Fired Equipment
4 Materials and Manufacture 8.5 Operation Procedures for Sand Preparation, Molding, and Coremaking
4 Materials and Manufacture 8.5 Operation Procedures for Sand Preparation, Molding, and Core Making
4.1 Responsibility 9 Melting and Pouring
4.2 Inherent Hazards 9.1 Cupola
4.3 Installation 9.2 Electric Furnaces – Induction Melting and Induction Holding
4.4 Power Requirements 9.3 Electric Furnaces – Direct Arc Furnaces
4.5 Electrical Ground Faults 9.4 Ladles
4.6 Fluid Power Off 9.5 Molten Metal Handling and Pouring Equipment
4.7 Electrical Equipment Grounding 9.6 Maintenance and Inspection
4.8 Fluid Exhaust (Gas or Liquid) 9.7 Molten Metal Treatment
5 Care of Equipment – General Provisions 9.8 Specific Material Handling Equipment
5.1 Instructions 9.9 Molten Metal Handling and Pouring
5.2 Installation 9.10 Overhead Handling of Molten Material
5.3 Inspection and Preventive Maintenance 10 Cleaning and Finishing
5.4 Maintenance Personnel Training and Experience 10.1 Care of Cleaning and Finishing Equipment
5.5 Startup Procedure 10.2 Specific Equipment Safeguards – Cleaning and Finishing
5.6 Shutdown Procedure 10.3 Abrasive Blasting
5.7 Troubleshooting, Maintenance, and Repair 10.4 Chipping
6 Safeguards – General Requirements 10.5 Abrasive Wheels
6.2 Responsibility for Safeguarding 10.6 Operating Procedures for Abrasive Wheels
6.1 Responsibility for Safeguarding 10.6 Operating Procedures for Abrasive Wheels
6.3 Guarding 10.7 Portable Abrasive Wheels
6.2 Guarding 10.7 Portable Abrasive Wheels
This practice is under the jurisdiction of ASTM Committee E34 on Occupational Health and Safety and is the direct responsibility of Subcommittee E34.10 on Industrial
Safety.
Current edition approved Oct. 1, 2018March 1, 2019. Published November 2018March 2019. Originally approved in 2005. Last previous edition approved in 20122018
as E2349 – 12.E2349 – 18. DOI: 10.1520/E2349-18.10.1520/E2349-19.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E2349 − 19
Contents
6.4 Hazard Zone Guarding 10.8 Grinding Magnesium
6.3 Hazard Zone Guarding 10.8 Grinding Magnesium
6.5 Hazard Zone Protective Devices 10.9 Molten Salts Cleaning
6.4 Hazard Zone Protective Devices 10.9 Molten Salts Cleaning
7 Operation of Equipment – General Requirements 10.10 Hooks Designed for Handling Castings
7.1 Employer’s Responsibility 10.11 Slings
7.2 Employee’s Responsibility 10.12 Lighting
8 Sand Preparation, Molding, and Coremaking 11 Keywords
8 Sand Preparation, Molding, and Core Making 11 Keywords
8.1 Sand Handling and Preparation
1. 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,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, health, and environmental practices and determine the applicability of
regulatory limitations prior to use.
1.7 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 ASTM Standards:
E1542 Terminology Relating to Occupational Health and Safety
F1002 Performance Specification for Protective Clothing and Materials for Use by Workers Exposed to Specific Molten
Substances and Related Thermal Hazards
F1449 Guide for Industrial Laundering of Flame, Thermal, and Arc Resistant Clothing
G88 Guide for Designing Systems for Oxygen Service
G128/G128M Guide for Control of Hazards and Risks in Oxygen Enriched Systems
2.2 ANSI Standards:
ANSI A12.64.1ANSI/ASSP A1264.1 Safety Requirements for Workplace, Floor and Wall Openings, Stairs and RailingWork-
place Walking/Working Surfaces and Their Access; Workplace, Floor, Wall, and Roof Openings; Stairs and Guardrail/Handrail
Systems
ANSI A58.1 Minimum Design Load in Buildings and Other Structures
ANSI B5.35 Machine Mounting for Abrasive Discs and Plate Mounted Wheels
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, http://www.ansi.org.
E2349 − 19
ANSI B 11.6 Safety Requirements for Manual Turning Machines with or without Automatic Control
ANSI B7.1 Safety Requirements for the Use, Care and Protection of Abrasive Wheels.
ANSI B11.6 Safety Requirements for Manual Turning Machines with or without Automatic Control
ANSI B11.9 Grinding Machines, Safety Requirements for the Construction, Care and Use of Grinding Machines
ANSI B11 TR3B11.TR3 Risk Assessment and Risk Reduction—A Guide to Estimate, Evaluate and Reduce Risks Associated
with Machine Tools
ANSI B15.1 Mechanical Power Transmission Apparatus
ANSI B20.1 Safety Standard for Conveyors and Related Equipment (ASME B20.1)
ANSI/ASME B30.2 Overhead and Gantry Cranes (Top Running, Bridge, Single or Multiple Girder Top Running Trolley Hoist)
ANSI/ASME B30.9 Slings
ANSI/ASME B30.10 Hooks
ANSI/ASME B30.11 Monorails and Underhung Cranes
ANSI/ASME B30.20 Below-the-hook Lifting Devices
ANSI B107.4 Driving & Spindle Ends for Portable Hand, Air and Electric Tools (Percussion Tools Excluded)
ANSI B186.1 Portable Air tools
ANSIANSI/ASSP Z9.2 Fundamentals Governing the Design and Operation of Local Exhaust Ventilation Systems
ANSIANSI/ASSP Z9.4 Ventilation and Safe Practices of Abrasive Blasting Operations
ANSI Z33.1 Standard for the Installation of Blower and Exhaust Systems (NFPA 91)
ANSI Z43.1ANSI/ASSP Z244.1 Ventilation Control of Grinding, Polishing/BuffingControl of Hazardous Energy Lockout,
Tagout, and Alternative Methods
ANSI Z244.1ANSI/ASSP Z359 Personnel Protection—Lockout/Tagout of Energy Sources—Minimum Safety RequirementsFall
Protection
ANSIANSI/ASSP Z490.1 Criteria for Accepted Practices in Safety, Health and Environmental Training
ANSI Z535.1 Safety Color Code
ANSI Z535.2 Environmental and Facility Safety Signs
ANSI Z535.3 Criteria for Safety Symbols
ANSI Z535.4 Product Safety Signs and Labels
ANSI Z535.5 Accident Prevention Tags
2.3 ASME Standards:
ASME B5.35 Machine Mounting for Abrasive Discs and Plate-Mounted Wheels
ASME B107.4 Driving & Spindle Ends for Portable Hand, Air and Electric Tools (Percussion Tools Excluded)
ASME B20.1 Safety Standard for Conveyors and Related Equipment (ASME B20.1)
ASME B30.2 Overhead and Gantry Cranes (Top Running, Bridge, Single or Multiple Girder Top Running Trolley Hoist)
ASME B30.5 Safety Code for Crawler, Locomotive, and Truck Cranes
ASME B30.9 Slings
ASME B30.10 Hooks
ASME B30.11 Monorails and Underhung Cranes
ASME B30.20 Below-the-Hook Lifting Devices
2.4 CGA Standard:
CGA G-4.4 Industrial Practices for Gaseous Oxygen Transmission and Distribution Piping Systems
2.5 IAPMO Document:
Uniform Plumbing Code
2.6 IES Document:
Lighting Handbook
2.7 NFPA Standards:
NFPA 49 Fire Protection Guide to Hazardous Materials
NFPA 53 Recommended Practice on Materials, Equipment and Systems Used in Oxygen-Enriched Atmospheres
NFPA 55 Compressed Gases and Cryogenic Fluids Code
NFPA 68 Guide for Venting of Deflagrations
NFPA 70 National Electrical Code
NFPA 70E Standard for Electrical Safety in the Workplace (Includes Arc-Flash)
NFPA 79 Electrical Standard for Industrial Machinery
Available from American Society of Mechanical Engineers (ASME), ASME International Headquarters, Two Park Ave., New York, NY 10016-5990, http://
www.asme.org.
Available from Compressed Gas Association (CGA), 14501 George Carter Way, Suite 103, Chantilly, VA 20151, http://www.cganet.com.
Available from International Association of Plumbing and Mechanical Officials, 4755 E. Philadelphia St., Ontario, CA 91761, http://www.iapmo.org.
Available from Illuminating Engineering Society (IES), 120 Wall Street, New York, NY 10005-4001, http://www.ies.org.
Available from National Fire Protection Association (NFPA), 1 Batterymarch Park, Quincy, MA 02169-7471, http://www.nfpa.org.
E2349 − 19
NFPA 86 Standard for Ovens and Furnaces
NFPA 91 Standard for the Installation of Blower and Exhaust Systems
NFPA 480 Standard for Storage and Handling of Magnesium
NFPA 484 Standard for Combustible Metals
2.8 Occupational Safety and Health Administration:
29 CFR 1910 Code of Federal Regulations, Part 1910 General Industry
29 CFR 1910.23 Guarding Floor and Wall Openings and HolesWalking-Working Surfaces
29 CFR 1910.94(a) Ventilation—Abrasive Blasting
29 CFR 1910.145 Specification for Accident Prevention Signs and Tags
29 CFR 1910.146 Permit required Permit-Required Confined Spaces
29 CFR 1910.147 Control of Hazardous Energy (LOCKOUT/TAGOUT)(Lockout/Tagout)
29 CFR 1910.184 Slings
29 CFR 1910.215 Abrasive Wheel Machinery
29 CFR 1910.217 Mechanical Power Presses
29 CFR 1910.331–335 Electrical Safety-Related Work Practices
OSHA Instruction STD 1-12.8 October 30, 1978 (Program Directive #100-39) Subject: 29 CFR 1910.215(a)(4) Abrasive Wheel
Machinery—Work Rests
NOTE 1—State plan states may have their own regulations.
2.9 American Foundry Society (AFS):
Guide for Selection and Use of Personal Protective Equipment and Guide for Selection and Use of Personal Protective
Equipment and Special Clothing for Foundry Operations Managing the Foundry Indoor Air Environment
Foundry Health and Safety Guides
3. Terminology
3.1 For definitions of terms used in this standard, see Terminology E1542.
3.2 Definitions:
3.2.1 abrasive blasting, n—operation in which an abrasive is forcibly applied to a surface by pneumatic or hydraulic pressure
or centrifugal force.
3.2.1 adjustable barrier guard, n—physical barrier with adjustable sections that prevents is designed to prevent entry of any part
of the body into the hazard zone by reaching through, over, under, or around the barrier. The adjustable sections allow different
jobs to be run on the equipment.
3.2.2.1 Discussion—
This type of guard requires close supervision of use and adjustment or inadequate protection could result. It shall be the
responsibility of the employer to establish and follow a program of periodic and regular inspection of power press and auxiliary
equipment. Refer to 29 CFR 1910.217(e).
3.2.2 arc furnace, n—see direct arc furnace and indirect arc furnacefurnace.
3.2.4 automatic, adv—each function in the machine cycle is initiated by the previous cycle and is automatically performed and
sequenced, including load, unload, and repeat cycle.
3.2.3 bail/spreader, n—hoop or arched connection between the crane hook and ladle or between crane hook and ladle trunnions.
3.2.6 barrier guard—see adjustable barrier guard, fixed barrier guard, and interlocked barrier guard.
3.2.4 blast, n—in foundry operations, air or oxygen-enriched air that is blown, under pressure, into a cupola for supporting
combustion.
3.2.5 blast compartment, n—that portion of the blasting enclosure that contains the blasting media propulsion device.
3.2.6 blow plate, n—plate affixed to the magazine or blow head of a core- or mold-blowing machine having holes or slots
through which sand or other media in the magazine or blow head passes into the core or mold cavity or around the pattern when
air or other gas pressure is applied to the machine.
3.2.7 bottom discharge (pour, tap) ladle, n—ladle that has its molten metal contents discharged through an opening in the
bottom.
3.2.8 channel furnace, n—electric induction furnace in which heat is electrically induced in the metal in a refractory channel.
Available from Occupational Safety and Health Administration (OSHA), 200 Constitution Ave., NW, Washington, DC 20210, http://www.osha.gov.
Available from the American Foundry Society, 1695 N. Penny Lane, Schaumburg, IL 60173.
E2349 − 19
3.2.9 charge, n—in foundry operations, material introduced into a melting furnace for the production of molten metal.
3.2.13 charging, v—process of adding a charge to a furnace.
3.2.14 control circuit (electrical), n—circuit of a control apparatus or system that carries the electric signals directing the
performance of the controller, but does not carry the main power current.
3.2.15 controller, n—device or group of devices that serves to govern, in some predetermined manner, the electric power
delivered to the apparatus to which it is connected.
3.2.10 core, n—in foundry operations, preformed aggregate or collapsible insert placed in a mold to shape the interior or that
part of a casting that cannot be shaped by the pattern.
3.2.11 core binder(s), n—any material, liquid or solid, which is used to bond core aggregates.
3.2.12 corebox, n—a (wood, metal, or plastic) structure, the cavity of which has the shape of the desired core that is to be made
therein.
3.2.13 coreless furnace, n—electric induction furnace consisting of an induction coil surrounding a crucible or refractory lining
in which metal is melted or molten metal is retained.
3.2.14 core- or mold-blowing or shooting machine, n—machine for injecting sand or other media into the core or mold cavity
by means of compressed air or other gas.
3.2.21 counterweight, n—weight that corrects a state of unbalance and establishes static equilibrium.
3.2.15 crane ladle, n—ladle handled by an overhead crane.
3.2.16 crucible, n—in foundry operations, container used for the melting, holding, and pouring of metal.
3.2.17 cupola, n—in foundry operations, vertical shaft-type furnace for melting and/or producing molten metal by combusting
coke or other fuels using a blast, and possibly additional pure oxygen, that is introduced through the cupola tuyeres.
3.2.18 cupola drop, n—materials dropped from the cupola at the end of a heat.
3.2.19 direct arc furnace, n—furnace in which heat is produced by an electric arc between electrodes and the charge.
3.2.27 disconnecting means (electrical), n—device, or group of devices, or other means by which it is possible to disconnect
the conductors of the circuit from their source of supply.
3.2.28 disconnect switch (electrical), n—switching device used primarily for isolating a circuit or equipment from a source of
power.
3.2.20 drop area, n—in foundry operations, the area directly under the cupola that receives the hot bed coke or other hot
materials from the inside of the furnace when the bottom doors or side access door are opened.
3.2.21 drop zone, n—the zone adjacent to the drop area that is exposed to drop hazards during the dropping process.
3.2.22 dross, n—metal oxides or foreign matter, or both, that accumulates on the surface of nonferrous molten metal.
3.2.32 dust collector, n—air-cleaning device to remove particulate matter from exhaust systems before discharge to the
atmosphere.
3.2.33 exhaust system, n—system of air-moving equipment and ducts used to remove airborne contaminants from affected areas.
3.2.34 explosion vent, n—a device that is engineered as part of an enclosure, container, or vessel that is designed to release
pressure rapidly.
3.2.23 finishing, v—in foundry operations, attainment of a desired surface finish or finish characteristics by such means as
abrasive impingement, grinding, or polishing.
3.2.36 fixed barrier guard, n—securely attached physical barrier, not readily removable, that prevents entry of any part of the
body into the hazard zone by reaching through, over, under, or around the barrier.
3.2.37 flame detector, n—device, which senses the absence or presence of flame, for the purpose of controlling fuel line valves.
3.2.24 flask, n—in foundry operations, container, without top or bottom, used to contain the sand or other media while it is being
formed. It is made in two or more parts, the lower part called the drag and the upper part called the cope. Intermediate sections,
if any, are called cheeks.
3.2.25 flask lifting device, n—chains, rods, bails, cables, slings, and other materials used to support a load such as a flask for
turning, inverting, or transporting.
3.2.40 fuel-fired equipment (enclosed), n—specially heated chamber such as core oven, drying oven, thermal sand reclamation,
sand heater, or annealing oven.
3.2.26 gas handling system, n—the collective group of equipment that draws cupola gas from the furnace.
3.2.42 guarded, adj—shielded, fenced, enclosed, or otherwise protected by means of suitable enclosure, covers, casing, shield
guards, trough guards, barrier guard, railing guards, or guarded by location, or other protective devices, so as to reduce the possible
risk of personnel injury from accidental contact or approach, or in the case of spill guards, so as to reduce possibility of personnel
E2349 − 19
injury from material being spilled into the area protected. Where it is not feasible to guard against the hazard, or where the guard
itself creates a hazard, the potential hazard shall be marked prominently to warn of its existence.
3.2.43 guarded by location, adv—to be guarded by location or position in accordance with the height above a walkway,
platform, or workspace, any moving part shall be at least 8 ft (2.46 m) above same. However, pinch points of all descriptions and
moving projections shall not be guarded by location unless they are a minimum of 9 ft (2.74 m) above the pertinent floor. When
moving parts are remote from floors, platforms, walkways, other working levels, or by their location with reference to frames,
foundations, or structures that minimize the probability of accidental contact by personnel, they shall be considered to be guarded
by position or location. Remoteness from regular or frequent presence of public or employed personnel, in reasonable
circumstances, constitutes guarding by location.
3.2.44 hazard, n—a condition or series of conditions, either continuous, intermittent or instantaneous in nature that exists, or
could exist, such that bodily injury could result. Hazards include, but are not limited to, falling, pinching, crushing, cutting,
impaction, burning, concussion, suffocation, occupational disease, asphyxiation and/or electrocution.
3.2.45 hazard point, n—closest point within the hazard zone at which physical contact occurs between machine elements or
materials or both.
3.2.46 hazard zone, n—that area where a hazard exists and bodily injury could result upon direct exposure or contact with that
hazard.
3.2.27 heat, n—in foundry operations, stated weight of metal obtained from a period of melting in a cupola or furnace or the
time required to melt and process this material.
3.2.48 hopper, n—bulk container in which materials are stored.
3.2.49 hostage control, n—type of control in which the physical act of operating the initiator prevents operator exposure to the
motion or response produced by the initiator.
3.2.49.1 Discussion—
An initiator located a sufficient distance from the hazard zone that the operator cannot reach the point of operation during the
hazardous portion of the cycle, after operating the initiator, is an example.
3.2.50 hostage protection, n—means of minimizing personnel exposure to hazards by making it easier to perform an operation
in a prescribed manner through work piece or machine design or both.
3.2.51 inch control, n—hostage control, which causes machine motion in single or repeated small increments only when
controlled by manual pressure.
3.2.51.1 Discussion—
It is intended for use in setup or maintenance, but not in normal operation.
3.2.28 indirect arc furnace, n—furnace in which heat is produced by an electric arc between electrodes.
3.2.29 induction furnace—see channel furnace and coreless furnacefurnace.
3.2.54 initiator, n—device that causes an action of control(s) or power.
3.2.54.1 Discussion—
Typical operator initiators are pushbuttons, foot switches, manual starters, hand valves, and other valves with manual overrides.
Typical non-operator initiators are limit switches, pressure switches, temperature-actuated switches, flow switches, and
cam-actuated valves.
3.2.55 inspections, frequency of, n—frequent—daily to monthly intervals and periodic—from one- to twelve-month intervals.
3.2.56 interlock, n—device in a system which, when actuated, permits or prevents the operation of one or more components in
the system.
3.2.57 interlocked barrier guard, n—barrier interlocked with the machine power or control so that the machine cycle will stop
and cannot be initiated with the operating controls unless the guard, or the hinged or movable sections, effectively encloses the
hazard zone.
3.2.58 isolation switch—see disconnect switch
3.2.59 jamming (hooking), v—jamming (hooking) occurs when the work rest becomes improperly adjusted to such an extent
that the work piece is pulled between the abrasive wheel and the leading edge of the work rest by the grinding action of the wheel
resulting in possible injury to personnel.
E2349 − 19
3.2.59.1 Discussion—
Jamming (hooking) should not be confused with the use of work rest mounted tooling, pins, or pressure bars.
3.2.30 ladle handler, n—mechanism used to suspend, transport, raise and/or lower a ladle.
3.2.31 ladle pouring stand, n—structural device for supporting or tilting a ladle, or both.
3.2.32 lance, oxygen, n—device consisting of steel pipe, tubing, oxygen source, and controls.
3.2.32.1 Discussion—
Frequently used to open frozen tap or slag holes; also occasionally to oxidize impurities in molten metal bath.
3.2.33 lip, n—in foundry operations, formed “U” or “V” depression in a molten metal outlet to confine the stream.
3.2.34 main burner, n—primary combustion device commonly ignited by a secondary source.
3.2.65 mandatory safety standards, n—those safety standards that are legally enforceable by agencies of federal, state, or local
government.
3.2.66 manual, adj—each machine function in the machine cycle and load cycle is manually initiated and controlled in the
sequence or out of the sequence of the normal machine cycle.
3.2.67 manually powered machines, n—machine in which the operator provides the motive power to operate the machine.
3.2.68 manual mode, n—method of operation that requires manual initiation of each function in the equipment cycle.
3.2.35 mold, n—in foundry operations, form that contains the cavity into which molten metal is poured to produce a casting of
definite shape and outline.
3.2.36 molding machine, n—machine mechanical device for compacting molding media (usually sand) about the pattern(s), thus
forming the mold.
3.2.37 moving frame, n—that part of a molding machine that supports the flask and imparts the motions necessary to the mold
making process.
3.2.38 muller, n—machine that blends, coats, kneads, or mechanically combines various sand(s) or other media used for foundry
purposes with binders and other additive agents. Typically, it consists of a circular container in which rotating plows or mill wheels
(mullers) or both are mounted.
3.2.38.1 Discussion—
Typically, it consists of a circular container in which rotating plows or mill wheels (mullers), or both, are mounted.
3.2.73 nip point, n—point or zone in which a part of the body could be caught and squeezed between two surfaces, edges, or
points.
3.2.74 operator’s work zone(s), n—operator’s work zone(s) of equipment is that area in which the operator’s presence is
required while operating in the intended manner.
3.2.74.1 Discussion—
An employee’s presence applies to the entrance into the operator’s work zone of the employee’s body or any part thereof.
3.2.39 pattern, n—in foundry operations, form of wood, metal, or other material against which molding material is compacted
to make a mold for casting metals.
3.2.76 pilot (flame or spark), n—auxiliary source that ignites the main burner.
3.2.77 pinch point, n—zone in which a portion of the body could be caught and injured between surfaces, edges, or points.
3.2.78 point of operation, n—that point or zone in which the principal operation is being performed.
3.2.40 pouring, n—in foundry operations, final transfer of molten metal before its solidification into its intended form.
3.2.41 pouring area, n—location in a foundry where molten metal is poured into molds or transferred from a ladle to a furnace.
3.2.81 power locked off, n—state in which the device that turns power off is locked in the off position with the padlock of every
individual who is working on the machine. Locks are affixed directly to the power disconnect, to a group lockout device, group
lockbox, or comparable mechanism.
3.2.82 power off or out, n—state in which power cannot flow to the equipment from the source (see 4.4).
3.2.83 presence-sensing device, n—device designed, constructed, and arranged to create a sensing field or area that will detect
either the presence or absence of personnel.
E2349 − 19
3.2.84 protection from unexpected machine movement, n—see protection, primary and protection, secondary.
3.2.84.1 Discussion—
There are hazards other than unexpected movement, and the OSHA machine lockout/tagout standard 29 CFR 1910.147 includes
protection against such other hazards.
3.2.85 protection, primary, n—state in which the primary source(s) of power has been isolated by being locked out (off) and
in which stored energy in the machine has been dissipated, constrained, or controlled. The state in which OSHA lockout/tagout
has been established.
3.2.85.1 Discussion—
Locking out the power to an electric drive motor by means of the main disconnect switch is an example of primary protection
against hazards related to the running of the motor.
3.2.86 protection, secondary, n—limited protection by control devices.
3.2.86.1 Discussion—
It is possible for control devices, like limit switches, to malfunction mechanically or electrically, and interlocks intended for safety
purposes are sometimes bypassed or wedged or tied in actuated states. Secondary protection is only justifiable when there is no
practical alternative, that is, when primary protection is not practical and when regular disciplined maintenance is present. The
operator, whose constant attitude should be one of caution, should understand the fact that operator protection devices such as
interlocked guards are secondary protection. Frequent inspections of such protective devices should be made. Locking a STOP
push button in the actuated position instead of using OSHA lockout/tagout is an example of a dangerous attempt to use secondary
protection against machine movement.
3.2.87 protective device, n—means whereby personnel access to a hazard zone or area is denied by other than a physical guard.
3.2.87.1 Discussion—
Protective devices include, but are not limited to, two-hand controls, two-hand trips, and hostage controls.
3.2.88 puncture point, n—zone in which a part of the body could be punctured or perforated.
3.2.42 qualified engineer, n—qualified engineer is one who possesses an engineering degree from an accredited institution of
higher learning or a certificate of professional standing and has engineering experience with the kind of work and equipment
involved.
3.2.43 qualified person, n—personindividual determined by the employer to have the training orand experience or both to safely
operate or maintain or both the equipment involved.
3.2.44 reactive metal, n—any metal metallic element or alloy that is readily oxidized with the release of large quantities of heat.
3.2.45 runout pit, n—pitchamber placed below or in front of a furnace, or both, to receive molten material in an emergency.
3.2.93 safety, n—state of being reasonably free or reasonably protected from injury or risk. Never to be construed as absolute
or perfect protection from harm, injury, or risk.
3.2.46 sand mixer, n—machine for conditioning mold and core sand by controlled mixing with additives.
3.2.47 sand muller, n—machine for conditioning mold and core sand by controlled mixing with additives.
3.2.48 sand system, n—that part of a foundry installation that processes and transports sand or other media in bulk form.
3.2.49 screen (sand), n—sieve or riddle with openings of definite size used to separate one grain size from another or to remove
lumps and foreign objects from sand.
3.2.98 semiutomatic, adj—at least one machine function in the cycle is automatically performed and sequenced, but which
requires the operator to initiate at least one function manually.
3.2.99 semiautomatic mode, n—method of operation in which at least one function in an equipment cycle requires manual
initiation and at least one function is automatically sequenced.
3.2.100 shear pin, n—pin built into a mechanism designed to fail under specified loading and act as an overload disconnect.
3.2.101 shear point, n—point or zone in which body parts could be caught by one machine member moving past another.
3.2.102 shutdown, n—planned steps required to take machine or process out of operation.
E2349 − 19
3.2.50 skimming, n—in foundry operations, removing slag or dross from the surface of the molten metal.
3.2.51 skip hoist, n—basket, bucket, or other container that is drawn or elevated on rails by a pulling or pushing action.
3.2.52 slag, n—nonmetallic byproducts and contaminants generated during the melting, transferring, and holding of molten
metal.
3.2.53 slagging, v—see skimming.
3.2.54 slag hole or door, n—opening in the furnace through which slag is removed.
3.2.55 slinger, n—machine that throws sand or other media into a flask, corebox, or other container.
3.2.109 start up, n—planned steps required to place a machine or process into operation.
3.2.110 stop block, n—rigid restraining device that will prevent hazardous movement of a machine or equipment member(s).
A stop block shall be designed and constructed to withstand the forces to which it will be subjected.
3.2.56 tapping, v—in foundry operations, removing molten material from the furnace by opening a tap hole.
3.2.57 transfer car, n—in foundry operations, vehicle used for transporting vessels or material(s), usually in a fixed path.
3.2.58 trunnions, n—shafts used to support, turn, or tilt a vessel.
3.2.59 tumbling barrel, n—power-driven rotating drum or barrel in which castings are cleaned or polished, or both. The castings
act as abrasives for each other or are tumbled in an abrasive media.
3.2.60 tuyere, n—nozzle opening through which the blast enters a cupola.
3.2.116 two-hand control, n—type of control in which the operator causes a motion by manually operating an initiator
concurrently with each hand, the motion stopping or reversing upon deactuation of either or both initiators.
3.2.117 two-hand trip device, n—type of control in which the operator causes a motion by manually operating an initiator
concurrently with each hand, the motion continuing to completion whether the initiators continue to be held actuated or not.
3.2.118 work zone and work station, n—see operator’s work zone(s)
4. Materials and Manufacture
4.1 Responsibility—It shall be the responsibility of any person purchasing, constructing, reconstructing, or modifying any
equipment covered by this practice to:
4.1.1 Design, construct, and modify equipment in accordance with the provisions of this practice. (Consider other applicable
safety standards.)
4.1.2 Select and include in construction only components that have a working rating equal to or greater than that required to
meet the maximum recommended operating condition(s).
4.1.3 Furnish printed instructions with each unit of equipment. (To minimize hazards, it is essential that this material be readily
available to maintenance, operations, and engineering personnel.) The instructions shall include:
4.1.3.1 Engineering drawings and other materials required to install and place such equipment into operation properly.
4.1.3.2 Operating and maintenance instructions as specified in Section 5.
4.1.3.3 Spare parts lists.
4.1.3.4 Procedures in accordance with 29 CFR 1910.147 OSHAhazardous energy control (6.5 lockout/tagout ) standard shall
be followed.
4.1.4 Hazard alert signs, when used, shall comply with the following standards: ANSI Z535.1 Safety Color Code, ANSI Z535.2
Environmental and Facility Safety Signs, ANSI Z535.3 Criteria for Safety Symbols, ANSI Z535.4 Product Safety Signs and
Labels, ANSI Z535.5 Accident Prevention Tags.Z535.1, ANSI Z535.2, ANSI Z535.3, ANSI Z535.4, and ANSI Z535.5.
4.1.5 Apply a legible identification plate to each piece of equipment. This plate shall include, as a minimum, the manufacturer’s
name, equipment type or model identification, or both, serial number, and rated capacity(s).
4.1.6 Ensure that any modification(s) or alteration(s) to a piece of equipment or machinery covered by this practice that result
in a change from the manufacturer’s original design or intended method of operation, or both, shall be done under the supervision
of a qualified engineer and shall comply with mandatory safety standards for that given category of equipment. An additional
legible identification plate shall be attached to the machine or equipment adjacent to the manufacturer’s original identification plate
(see 4.14.1.5 (5)). ). The new identification plate shall state the date the modification(s) was made and the person or organization
responsible. (Restrictions on modifications or alterations are not intended to bar repair or maintenance, including the substitution
of substantially equivalent components.)
4.2 Inherent Hazards:
4.2.1 Hazards to Personnel Associated withWith Moving Parts—Hazards to personnel associated with moving parts (other than
point of operation hazards) shall be guarded in accordance with ANSI B15.1 or ANSIASME B20.1, as appropriate.
4.2.1.1 Discussion—Some examples of hazards to personnel associated with moving parts are:
(1) Rotating components, such as flywheels, gears, sheaves, and shafts in proximity to personnel;
(2) Run-in pinch points, such as meshing gears, belts, and chains; and
E2349 − 19
(3) Pinch points between the moving and stationary components of the machine.
NOTE 2—Some examples of hazards to personnel associated with moving parts are:
(1) Rotating components, such as flywheels, gears, sheaves, and shafts in proximity to personnel;
(2) Run-in pinch points, such as meshing gears, belts, and chains; and
(3) Pinch points between the moving and stationary components of the machine.
4.2.1.1 Responsibility – Manufacturer—The manufacturer shall endeavor to eliminate the hazards by design or provide
protection against them. When hazards cannot be eliminated by design or protection, the manufacturer shall warn against them by
using signs in accordance with ANSI Z535.1, 2, 3, 4, 5, ANSI Z535.2, ANSI Z535.3, ANSI Z535.4, and ANSI Z535.5, as
appropriate.
NOTE 3—Together, these five ANSI standards contain information needed to specify formats, colors, and symbols for safety signs used in environmental
and facility applications, product applications, and accident prevention signs.
4.2.1.3 Discussion—Together, these five ANSI standards contain information needed to specify formats, colors, and symbols for
safety signs used in environmental and facility applications, product applications, and accident prevention signs.
4.2.1.2 Responsibility – Employer—Equipment with moving parts that could cause injuries to personnel shall be guarded.
4.2.2 Hazards to Personnel Associated With the Point of Operation—Refer to Section 6.
4.2.3 Hazards to Personnel Associated With Broken, Falling, or Flying Equipment Components—The manufacturer shall
design, secure, or cover machine components to minimize hazards caused by falling or flying components resulting from loosening
or breakage.
4.3 Installation:
4.3.1 Employer Responsibility—The employer shall be responsible for safe conditions for installing the equipment covered by
this practice.
4.3.2 Safeguarding During Construction, Reconstruction, or Modification—Use of barriers, shields, and covers over
excavations, pits, or tanks shall be required and used. Means shall be provided to prevent unauthorized persons from entering an
area or zone in which construction or repair is in progress.
4.3.2.1 Discussion—ANSI A12.64.1 contains the appropriate requirements and recommendations.
NOTE 4—ANSI/ASSP A1264.1 contains the appropriate requirements and recommendations.
4.3.3 Workstation—Each workstation shall have space to permit work without physical interference from equipment or another
employee(s) within that workstation. Services, including electric power, air hydraulic, water, steam, or process liquids, shall be
delivered in identified conductors with shutoff valves or disconnecting means legibly marked, and shall be visible and accessible.
4.4 Power Requirements:
4.4.1 Disconnect Means—All motors, motor circuits, and controllers shall have disconnecting means as required by Article 430
of the National Electric Code (ANSI/NFPA(NFPA 70). The disconnecting means shall be capable of being locked in the (OFF)
position.
4.4.1.1 Disconnect Means Identification—Each disconnect means shall be marked with a legible, durable label that identifies
the voltage and equipment controlled. Identification shall be verified at time of installation.
4.4.1.2 Disconnection:
(1) Control circuits shall be so arranged that they will be disconnected from all sources of power when disconnecting means
is in the open (OFF) position.
(2) There shall be an interlock, on separate power source feeds, that opens when the main disconnect is opened.
(3) The disconnecting means consists of two or more separate devices, one of which disconnects the motor and the controller
from the source(s) of power supply for the motor, and the other disconnects the control circuit(s) from its power source. Where
separate devices are used, they shall be located immediately adjacent, one to the other.
4.4.1.3 Disconnection Hazards—Where the operation of a disconnecting means could create a hazard, a suitable hazard alerting
nameplate shall be provided and located adjacent to the label required in 4.4.1.1
4.4.1.4 Motor-Starting Equipment—Motor-starting equipment with the potential to restart a motor automatically after an
unplanned power interruption or power outage shall not be used when automatic restarting would potentially result in injury to
personnel. It shall be necessary to restart the motor manually.
4.4.2 Electrical Power Off – Electrical Panels or Electrical Furnaces:
4.4.2.1 Disconnect Means—All control and power circuits shall be equipped with disconnecting means that have the capability
to be locked in the open (OFF) position for the protection of the operating or maintenance personnel.
4.4.2.2 Isolation (Disconnect) Switches—Isolation switches not capable of interrupting load current shall not be opened under
load and shall be provided with signage warning against opening under load.
4.4.2.3 Discussion—Where possible, these isolation switches shall be key interlocked with the circuit-interrupting device so that
the isolation switch cannot be opened under load. Individual consideration shall be given to keep these switches in a locked closed
(ON) condition during normal operation.
E2349 − 19
4.4.2.4 Door Interlock—All doors providing access to electrical circuits that operate at over 50 V shall be interlocked to
disconnect electrical power when the door is opened. If voltages in excess of 50 V remain after electrical power has been
disconnected, hazard alert signs shall be provided.
4.4.2.5 Discussion—While power has been disconnected when the door is opened, electrical power remains at the primary
terminals. In addition, in some instances capacitors will remain charged and must be dischar
...