1、Designation: E 2349 09Standard 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 () indicates an editorial change since the last revision or reapproval.INTRODUCTIONThis practice is part of a project started in 1
3、972 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 req
4、uiring 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 exi
5、sts. 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. Thispractice is not intended to supersede or replace any applicable federal, state, or local governm
6、entalsafety regulations or requirements, but rather, it is intended to augment and support any suchrequirements. 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 fundamentalrequire
7、ment in preventing occupational injuries.ContentsIntroduction1. Scope 8.2 Core Making2. Referenced Documents 8.3 Molding Equipment3. Terminology 8.4 Fuel-Fired Equipment4. Materials and Manufacture 8.5 Operation Procedures for Sand Preparation, Molding, and Coremaking4.1 Responsibility 9. Melting an
8、d Pouring4.2 Inherent Hazards 9.1 Cupola4.3 Installation 9.2 Electric FurnacesInduction Melting and Induction Holding4.4 Power Requirements 9.3 Electric FurnacesDirect Arc Furnaces4.5 Electrical Ground Faults 9.4 Ladles4.6 Fluid Power Off 9.5 Molten Metal Handling and Pouring Equipment4.7 Electrical
9、 Equipment Grounding 9.6 Maintenance and Inspection4.8 Fluid Exhaust (Gas or Liquid) 9.7 Molten Metal Treatment5. Care of EquipmentGeneral Provisions 9.8 Specific Material Handling Equipment5.1 Instructions 9.9 Molten Metal Handling and Pouring5.2 Installation 9.10 Overhead Handling of Molten Materi
10、al5.3 Inspection and Preventive Maintenance 10. Cleaning and Finishing5.4 Maintenance Personnel Training and Experience 10.1 Care of Cleaning and Finishing Equipment5.5 Startup Procedure 10.2 Specific Equipment SafeguardsCleaning and Finishing5.6 Shutdown Procedure 10.3 Abrasive Blasting5.7 Troubles
11、hooting, Maintenance and Repair 10.4 Chipping6. SafeguardsGeneral Requirements 10.5 Abrasive Wheels6.2 Responsibility for Safeguarding 10.6 Operating Procedures for Abrasive Wheels6.3 Guarding 10.7 Portable Abrasive Wheels6.4 Hazard Zone Guarding 10.8 Grinding Magnesium6.5 Hazard Zone Protective Dev
12、ices 10.9 Molten Salts Cleaning7. Operation of EquipmentGeneral Requirements 10.10 Hooks Designed for Handling Castings7.1 Employers Responsibility 10.11 Slings7.2 Employees Responsibility 10.12 Lighting8. Sand Preparation, Molding, and Coremaking 11. Keywords8.1 Sand Handling and Preparation1Copyri
13、ght ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.1. Scope1.1 This practice covers the requirements of applying thedesign, construction, and operation of the machinery andequipment used in metal casting operationssand preparation,molding and
14、core making, melting and pouring, and cleaningand finishing. This practice does not apply to die castingoperations.1.2 PurposeThe requirements of this practice, includingthe training of supervisors and employees, are intended tominimize the possibility of injury to operating and maintenancepersonnel
15、 while working on, or in the vicinity of, the specifiedequipment. Compliance with this practice, in conjunction withOSHA regulations, provides a relatively safe environment,which is a fundamental requisite in helping to prevent occu-pational injuries.1.3 Application1.3.1 New InstallationsAfter the d
16、ate of publication, allnew installations within the scope of this specification shall bein conformance with its requirements. Any existing machineinstallation moved to a new plant or another location in thesame plant is deemed a new installation when it is installed inthe new location. However, an e
17、xisting installed machine(former installation) that is moved for a short distance, forexample, to provide additional aisle space, is not deemed to bea new installation.1.3.2 Existing InstallationsAfter the approval date of thispractice, installations existing on, or before, this date, shall bemodifi
18、ed 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 practice, deficienciesshall be noted and plans for compliance shall be included inany future facility or equipment changes. Those facilities
19、andequipment on order or in the process of construction on thedate of publication of this practice shall be considered as anexisting installation. This practice applies to existing equip-ment if it lacks the necessary employee protection (personalprotective equipment or administrative controls).1.4
20、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 notes and footnoteswhich provide explanatory material. These notes and footnotes(excluding those in tables and figures) shall not be consi
21、deredas 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 theresponsibility of the user of this standard to establish appro-priate safety and health practices and to determine theapplicability of regulatory li
22、mitations prior to use.2. Referenced Documents2.1 ASTM Standards:2F 1002 Performance Specification for Protective Clothingfor Use by Workers Exposed to Specific Molten Substancesand Related Thermal HazardsF 1449 Guide for Industrial Laundering of Flame, Thermal,and Arc Resistant Clothing2.2 ANSI Sta
23、ndards:3ANSI A12.64.1 Safety Requirements for Workplace, Floorand Wall Openings, Stairs and Railing SystemsANSIA58.1 Minimum Design Load in Buildings and OtherStructuresANSI B5.35 Machine Mounting for Abrasive Discs andPlate Mounted WheelsANSI B 11.6 Safety Requirements for Manual TurningMachines wi
24、th or without Automatic ControlANSI B7.1 Safety Requirements for the Use, Care andProtection of Abrasive Wheels.ANSI B11.9 Grinding Machines, Safety Requirements forthe Construction, Care and Use ofANSI B11 TR3 Risk Assessment and Risk ReductionAGuide to Estimate, Evaluate and Reduce Risks Associate
25、dwith Machine ToolsANSI B15.1 Mechanical Power Transmission ApparatusANSI B20.1 Safety Standard for Conveyors and RelatedEquipment (ASME B20.1)ANSI/ASME B30.2 Overhead and Gantry Cranes (TopRunning, Bridge, Single or Multiple Girder Top RunningTrolley Hoist)ANSI/ASME B30.9 SlingsANSI/ASME B30.10 Hoo
26、ksANSI/ASME B30.11 Monorails and Underhung CranesANSI/ASME B30.20 Below-the-hook Lifting DevicesANSI B107.4 Driving also occasionally to oxidize impurities in moltenmetal bath.3.80 lip, nformed “U” or “V” depression in a moltenmetal outlet to confine the stream.3.81 lip pour ladle, nladle in which t
27、he contents aredischarged over a lip(s) at the top.3.82 lock pin, npin, when installed, designed specificallyto stop or limit motion of a machine element to attain OSHAlockout/tagout.3.83 main burner, nprimary combustion device com-monly ignited by a secondary source.3.84 mandatory safety standards,
28、 nthose safety standardsthat are legally enforceable by agencies of federal, state, orlocal government.3.85 manual, adjeach machine function in the machinecycle and load cycle is manually initiated and controlled in thesequence or out of the sequence of the normal machine cycle.3.86 manual mode, nme
29、thod of operation that requiresmanual initiation of each function in the equipment cycle.3.87 manually powered machines, nmachine in which theoperator provides the motive power to operate the machine.3.88 minimum guarding line, nthat distance between thepoint of entry side of the guard and the hazar
30、d point.3.89 mode of operation, nsee automatic, manual, andsemiautomatic.3.90 mold, nform that contains the cavity into whichmolten metal is poured to produce a casting of definite shapeand outline.3.91 molding machine, nmachine for compacting mold-ing media (usually sand) about the pattern(s), thus
31、 forming themold.3.92 moving frame, nthat part of a molding machine thatsupports the flask and imparts the motions necessary to themold making process.E23490953.93 muller, nmachine that blends, coats, kneads, ormechanically combines various sand(s) or other media used forfoundry purposes with binder
32、s and other additive agents.Typically, it consists of a circular container in which rotatingplows or mill wheels (mullers) or both are mounted.3.94 nip zone, npoint or zone in which a portion of thebody may be caught hold of and squeezed between twosurfaces, edges, or points.3.95 operators work zone
33、(s), noperators work zone(s) ofequipment is that area in which the operators presence isrequired while operating in the intended manner.3.95.1 DiscussionAn employees presence applies to theentrance into the operators work zone of the employees bodyor any part thereof.3.96 pattern, nform of wood, met
34、al, or other materialagainst which molding material is compacted to make a moldfor casting metals.3.97 pilot (flame or spark), nauxiliary source that ignitesthe main burner.3.98 pinch zone, nzone in which a portion of the bodymay be caught and injured between surfaces, edges, or points.3.99 point of
35、 operation, nthat point or zone in which theprincipal operation is being performed.3.100 pouring, nfinal transfer of molten metal before itssolidification into its intended form.3.101 pouring area, nlocation in a foundry where moltenmetal is poured into molds or transferred from a ladle to afurnace.
36、3.102 power off or out, nstate in which power cannot flowto the equipment from the source (see 4.4).3.103 power locked off, nstate in which the device thatturns power off is locked in the off position with the padlock ofevery individual who is working on the machine. Locks areaffixed directly to the
37、 power disconnect, to a group lockoutdevice, group lockbox, or comparable mechanism.3.104 presence-sensing device, ndevice designed, con-structed, and arranged to create a sensing field or area that willdetect either the presence or absence of personnel.3.105 protection from unexpected machine movem
38、ent,nsee protection, primary and protection, secondary.3.105.1 DiscussionThere are hazards other than unex-pected movement, and the OSHA machine lockout/tagoutstandard 29 CFR 1910.147 includes protection against suchother hazards.3.106 protection, primary, nstate in which the primarysource(s) of pow
39、er 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.3.106.1 DiscussionLocking out the power to an electricdrive motor by means of the main disconnect switch
40、 is anexample of primary protection against hazards related to therunning of the motor.3.107 protection, secondary, nlimited protection by con-trol devices.3.107.1 DiscussionControl devices, like limit switches,can malfunction mechanically or electrically, can be frustratedby a ground or short circu
41、it in the wiring to them, andinterlocks intended for safety purposes are often bypassed orwedged or tied in actuated states. Secondary protection is onlyjustifiable when there is no practical alternative, that is, whenprimary protection is not practical and when regular disciplinedmaintenance is pre
42、sent. The operator, whose constant attitudeshould be one of caution, should understand the fact thatoperator protection devices such as interlocked guards aresecondary protection. Frequent inspections of such protectivedevices should be made. Locking a STOP push button in theactuated position instea
43、d of using OSHA lockout/tagout is anexample of a dangerous attempt to use secondary protectionagainst machine movement.3.108 protective device, nmeans whereby personnel ac-cess to a hazard zone or area is denied by other than a physicalguard.3.108.1 DiscussionProtective devices include, but are notl
44、imited to, two-hand controls, two-hand trips, and hostagecontrols.3.109 puncture zone, nzone in which a portion of thebody may be punctured or perforated.3.110 qualified engineer, nqualified engineer is one whopossesses an engineering degree from an accredited institutionof higher learning or a cert
45、ificate of professional standing andhas engineering experience with the kind of work and equip-ment involved.3.111 qualified person, nperson determined by the em-ployer to have the training or experience or both to operate ormaintain or both the equipment involved.3.112 reactive metal, nany metal th
46、at is readily oxidizedwith the release of large quantities of heat.3.113 reclaimed sand, nused foundry sand, which hasbeen reprocessed by thermal, air, or hydraulic methods so thatit can be used in place of new sand without substantiallychanging current foundry sand practice.3.114 recuperative hot b
47、last operation, noperation of acupola in which effluent gases escaping from the cupola areused to preheat the blast.3.115 reverberatory furnace, nshallow bath furnace formelting metal in which the bath is heated by the combustion ofhot gases over the surface of the metal and by radiation fromthe roo
48、f.3.116 runout pit, npit placed below or in front of afurnace or both to receive molten material in an emergency.3.117 safety, nstate of being reasonably free or reason-ably protected from injury or risk. Never to be construed asabsolute or perfect protection from harm, injury, or risk.3.118 sand mi
49、xer, nmachine for conditioning mold andcore sand by controlled mixing with additives.3.119 sand muller, nmachine for conditioning mold andcore sand by controlled mixing with additives.3.120 sand system, nthat part of a foundry installationthat processes and transports sand or other media in bulk form.3.121 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.3.122 semiutomatic, adjat least one machine function inthe cycl
