1、Designation: E 2349 05Standard Practice forSafety Requirements in Metal Casting Operations: SandPreparation, Molding, and Core Making; Melting andPouring; and Cleaning and Finishing1This standard is issued under the fixed designation E 2349; the number immediately following the designation indicates
2、 the year oforiginal adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.INTRODUCTIONThis practice is part of a project started in
3、1972 under the sponsorship of the American FoundrySociety, Inc. Standard for Safety Requirements in Metal Casting OperationsSand Preparation,Molding, and Core Making; Melting and Pouring; and Cleaning and Finishing.The metal casting industry shares safety considerations with many other industries re
4、quiring themovement 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 thedevelopment of industry-wide standards wherever the need for safety considerations ex
5、ists. Thispractice, therefore, is limited to safety considerations of special importance in the metal castingindustry operations in which general standards do not exist or are not considered adequate. Operatingrules are not included in this practice unless they are vital to safety.Compliance with th
6、is practice should provide a relatively safe environment, which is a fundamentalrequirement in preventing occupational injuries.ContentsIntroduction 6.3 Hazardous Zone Guarding1. Scope 6.4 Hazardous Zone Protective Devices2. Referenced Documents 7. Operation of EquipmentGeneral Requirements3. Termin
7、ology 7.1 Employers Responsibility4. Materials and Manufacture 7.2 Employees Responsibility4.1 Responsibility 8. Sand Preparation, Molding, and Coremaking4.2 Inherent Hazards 8.1 Specific Equipment SafeguardsSand Preparation, Molding, and Coremak-ing4.3 Installation 8.2 Operation Procedures for Sand
8、 Preparation, Molding, and Coremaking4.4 Power Requirements 9. Melting and Pouring4.5 Electrical Ground Faults 9.1 Cupolas4.6 Fluid Power Off 9.2 Electric Furnaces - Induction Melting and Induction Holding4.7 Electrical Equipment Grounding 9.3 Electric FurnacesDirect Arc Furnaces4.8 Fluid Exhaust (G
9、as or Liquid) 9.4 Ladles5. Care of EquipmentGeneral Provisions 9.5 Molten Metal Handling and Pouring Equipment5.1 Instructions 9.6 Maintenance and Inspection5.2 Installation 9.7 Molten Metal Treatment5.3 Inspection and Preventive Maintenance 9.8 Specific Material Handling Equipment5.4 Maintenance Pe
10、rsonnel Training and Experience 9.9 Ladle Use5.5 Startup Procedure 9.10 Overhead Handling of Molten Material5.6 Shutdown Procedure 10. Cleaning and Finishing5.7 Troubleshooting, Maintenance and Repair 10.1 Care of Cleaning and Finishing Equipment6. SafeguardsGeneral Requirements 10.2 Specific Equipm
11、ent SafeguardsCleaning and Finishing6.1 Responsibility for Safeguarding 10.3 Operating Procedures for Cleaning and Finishing Equipment6.2 Guarding Within the Operators Work Zone 11. Keywords1. Scope1.1 This practice covers the requirements of applying thedesign, construction, and operation of the ma
12、chinery andequipment used in metal casting operationssand preparation,1This practice is under the jurisdiction of ASTM Committee E34 on Occupa-tional Health and Safety and is the direct responsibility of Subcommittee E34.20 onFoundry Safety and Health.Current edition approved May 1, 2005. Published
13、June 2005.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.molding and core making, melting and pouring, and cleaningand finishing. This practice does not apply to die castingoperations.1.2 PurposeThe requirements of this practice, in
14、cludingthe training of supervisors and employees, are intended tominimize the possibility of injury to operating and maintenancepersonnel while working on, or in the vicinity of, the specifiedequipment. Compliance with this practice, in conjunction withOSHA regulations, provides a relatively safe en
15、vironment,which is a fundamental requisite in helping to prevent occu-pational injuries.1.3 Application1.3.1 New InstallationsAfter the date of publication, allnew installations within the scope of this specification shall bein conformance with its requirements. Any existing machineinstallation move
16、d to a new plant or another location in thesame plant is deemed a new installation when it is installed inthe new location. However, an existing installed machine(former installation) that is moved for a short distance, forexample, to provide additional aisle space, is not deemed to bea new installa
17、tion.1.3.2 Existing InstallationsAfter the approval date of thispractice, installations existing on, or before, this date, shall bemodified as necessary to be in conformance with all require-ments of this practice. Where it is not practical to modify anexisting facility in conformance with this prac
18、tice, deficienciesshall be noted and plans for compliance shall be included inany future facility or equipment changes. Those facilities andequipment on order or in the process of construction on thedate of publication of this practice shall be considered as anexisting installation. This practice ap
19、plies to existing equip-ment if it lacks the necessary employee protection (personalprotective equipment or administrative controls).1.4 The values stated in inch/pound units are to be regardedas the standard. The values in brackets are for information only.1.5 The text of this practice references n
20、otes and footnoteswhich provide explanatory material. These notes and footnotes(excluding those in tables and figures) shall not be consideredas requirements of the standard.1.6 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibil
21、ity of the user of this standard to establish appro-priate safety and health practices and to determine theapplicability of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:2F 1002 Specification for Protective Clothing for Use byWorkers Exposed to Specific Molten Substan
22、ces and Re-lated Thermal HazardsF 1449 Guide for Care and Maintenance of Flame Resistantand Thermally Protective Clothing2.2 ANSI Standards:3ANSI A12.64.1 Safety Requirements for Workplace, Floorand Wall Openings, Stairs and Railing SystemsANSIA58.1 Minimum Design Load in Buildings and OtherStructur
23、esANSI B5.35 Machine Mounting for Abrasive Discs andPlate Mounted WheelsANSI B 11.6 Safety Requirements for Manual TurningMachines with or without Automatic ControlANSI B7.1 Safety Requirements for the Use, Care andProtection of Abrasive Wheels.ANSI B11.9 Grinding Machines, Safety Requirements forth
24、e Construction, Care and Use ofANSI B11 TR3 Risk Assessment and Risk ReductionAGuide to Estimate, Evaluate and Reduce Risks Associatedwith Machine ToolsANSI B15.1 Mechanical Power Transmission ApparatusANSI B20.1 Safety Standard for Conveyors and RelatedEquipment (ASME B20.1)ANSI/ASME B30.2 Overhead
25、 and Gantry Cranes (TopRunning, Bridge, Single or Multiple Girder Top RunningTrolley Hoist)ANSI/ASME B30.9 SlingsANSI/ASME B30.10 HooksANSI/ASME B30.11 Monorails and Underhung CranesANSI/ASME B30.20 Below-the-hook Lifting DevicesANSI B107.4 Driving also occasionally to oxidize impurities in moltenme
26、tal bath.3.74 lip, nformed “U” or “V” depression in a moltenmetal outlet to confine the stream.3.75 lip pour ladle, nladle in which the contents aredischarged over a lip(s) at the top.3.76 lock pin, npin, when installed, designed specificallyto stop or limit motion of a machine element to attain OSH
27、Alockout/tagout.3.77 main burner, nprimary combustion device com-monly ignited by a secondary source.3.78 mandatory safety standards, nthose safety standardsthat are legally enforceable by agencies of federal, state, orlocal government.3.79 manual, adjeach machine function in the machinecycle and lo
28、ad cycle is manually initiated and controlled in thesequence or out of the sequence of the normal machine cycle.3.80 manual mode, nmethod of operation that requiresmanual initiation of each function in the equipment cycle.3.81 manually powered machines, nmachine in which theoperator provides the mot
29、ive power to operate the machine.3.82 minimum guarding line, nthat distance between thepoint of entry side of the guard and the hazard point.3.83 mode of operation, nsee automatic, manual, andsemiautomatic.3.84 mold, nform that contains the cavity into whichmolten metal is poured to produce a castin
30、g of definite shapeand outline.3.85 molding machine, nmachine for compacting mold-ing media (usually sand) about the pattern(s), thus forming themold.3.86 moving frame, nthat part of a molding machine thatsupports the flask and imparts the motions necessary to themold making process.3.87 muller, nma
31、chine that blends, coats, kneads, ormechanically combines various sand(s) or other media used forfoundry purposes with binders and other additive agents.Typically, it consists of a circular container in which rotatingplows or mill wheels (mullers) or both are mounted.3.88 nip zone, npoint or zone in
32、 which a portion of thebody may be caught hold of and squeezed between twosurfaces, edges, or points.3.89 operators work zone(s), noperators work zone(s) ofequipment is that area in which the operators presence isrequired while operating in the intended manner.3.89.1 DiscussionAn employees presence
33、applies to theentrance into the operators work zone of the employees bodyor any part thereof.3.90 pattern, nform of wood, metal, or other materialagainst which molding material is compacted to make a moldfor casting metals.3.91 pilot (flame or spark), nauxiliary source that ignitesthe main burner.3.
34、92 pinch zone, nzone in which a portion of the bodymay be caught and injured between surfaces, edges, or points.3.93 point of operation, nthat point or zone in which theprincipal operation is being performed.3.94 pouring, nfinal transfer of molten metal before itssolidification into its intended for
35、m.3.95 pouring area, nlocation in a foundry where moltenmetal is poured into molds or transferred from a ladle to afurnace.3.96 power off or out, nstate in which power cannot flowto the equipment from the source (see 4.4).3.97 power locked off, nstate in which the device thatturns power off is locke
36、d in the off position with the padlock ofevery individual who is working on the machine. Locks areaffixed directly to the power disconnect, to a group lockoutdevice, group lockbox, or comparable mechanism.3.98 presence-sensing device, ndevice designed, con-structed, and arranged to create a sensing
37、field or area that willdetect either the presence or absence of personnel.3.99 protection from unexpected machine movement, nseeprotection, primary and protection, secondary.E23490553.99.1 DiscussionThere are hazards other than unex-pected movement, and the OSHA machine lockout/tagoutstandard 29 CFR
38、 1910.147 includes protection against suchother hazards.3.100 protection, primary, nstate in which the primarysource(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
39、 has been established.3.100.1 DiscussionLocking out the power to an electricdrive motor by means of the main disconnect switch is anexample of primary protection against hazards related to therunning of the motor.3.101 protection, secondary, nlimited protection by con-trol devices.3.101.1 Discussion
40、Control devices, like limit switches,can malfunction mechanically or electrically, can be frustratedby a ground or short circuit in the wiring to them, andinterlocks intended for safety purposes are often by-passed orwedged or tied in actuated states. Secondary protection is onlyjustifiable when the
41、re is no practical alternative, that is, whenprimary protection is not practical and when regular disciplinedmaintenance is present. The operator, whose constant attitudeshould be one of caution, should understand the fact thatoperator protection devices such as interlocked guards aresecondary prote
42、ction. Frequent inspections of such protectivedevices should be made. Locking a STOP push button in theactuated position instead of using OSHA lockout/tagout is anexample of a dangerous attempt to use secondary protectionagainst machine movement.3.102 protective device, nmeans whereby personnel ac-c
43、ess to a hazardous zone or area is denied by other than aphysical guard.3.102.1 DiscussionProtective devices include, but are notlimited to, two-hand controls, two-hand trips, and hostagecontrols.3.103 puncture zone, nzone in which a portion of thebody may be punctured or perforated.3.104 qualified
44、engineer, nqualified engineer is one whopossesses an engineering degree from an accredited institutionof higher learning or a certificate of professional standing andhas engineering experience with the kind of work and equip-ment involved.3.105 qualified person, nperson determined by the em-ployer t
45、o have the training or experience or both to operate ormaintain or both the equipment involved.3.106 reactive metal, nany metal that is readily oxidizedwith the release of large quantities of heat.3.107 reclaimed sand, nused foundry sand, which hasbeen reprocessed by thermal, air, or hydraulic metho
46、ds so thatit can be used in place of new sand without substantiallychanging current foundry sand practice.3.108 recuperative hot blast operation, noperation of acupola in which effluent gases escaping from the cupola areused to preheat the blast.3.109 reverberatory furnace, nshallow bath furnace for
47、melting metal in which the bath is heated by the combustion ofhot gases over the surface of the metal and by radiation fromthe roof.3.110 runout pit, npit placed below or in front of afurnace or both to receive molten material in an emergency.3.111 safety, nstate of being reasonably free or reasonab
48、lyprotected from injury or risk. Never to be construed as absoluteor perfect protection from harm, injury, or risk.3.112 sand mixer, nmachine for conditioning mold andcore sand by controlled mixing with additives.3.113 sand muller, nmachine for conditioning mold andcore sand by controlled mixing wit
49、h additives.3.114 sand system, nthat part of a foundry installation thatprocesses and transports sand or other media in bulk form.3.115 screen (sand), nsieve or riddle with openings ofdefinite size used to separate one grain size from another or toremove lumps and foreign objects from sand.3.116 semiutomatic, adjat least one machine function inthe cycle is automatically performed and sequenced, but whichrequires the operator to initiate at least one function manually.3.117 semiautomatic mode, nmethod of operation inwhic
