1、Designation: E2349 12Standard 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 E2349; the number immediately following the designation indicates t
2、he 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 197
3、2 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 requi
4、ring 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 exist
5、s. 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 governmen
6、talsafety 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 fundamentalrequireme
7、nt 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 and
8、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 E
9、quipment 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 Material
10、5.3 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 Troublesho
11、oting, 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 Devic
12、es 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 Preparation1Copyrigh
13、t 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 co
14、re 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 w
15、hile 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 dat
16、e 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 exi
17、sting 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 bemodified
18、 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 an
19、dequipment 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 Th
20、e 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 conside
21、redas 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 limi
22、tations prior to use.2. Referenced Documents2.1 ASTM Standards:2F1002 Performance Specification for Protective Clothingfor Use by Workers Exposed to Specific Molten Substancesand Related Thermal HazardsF1449 Guide for Industrial Laundering of Flame, Thermal,and Arc Resistant Clothing2.2 ANSI Standar
23、ds: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 with o
24、r 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 Associatedwit
25、h 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 HooksAN
26、SI/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.3.63 lip, nformed “U” or “V” depression in a moltenmetal outlet to confine the stream.3.64 main burner, nprimary combustion devi
27、ce com-monly ignited by a secondary source.3.65 mandatory safety standards, nthose safety standardsthat are legally enforceable by agencies of federal, state, orlocal government.3.66 manual, adjeach machine function in the machinecycle and load cycle is manually initiated and controlled in thesequen
28、ce or out of the sequence of the normal machine cycle.3.67 manual mode, nmethod of operation that requiresmanual initiation of each function in the equipment cycle.3.68 manually powered machines, nmachine in which theoperator provides the motive power to operate the machine.3.69 mold, nform that con
29、tains the cavity into whichmolten metal is poured to produce a casting of definite shapeand outline.3.70 molding machine, nmachine for compacting mold-ing media (usually sand) about the pattern(s), thus forming themold.3.71 moving frame, nthat part of a molding machine thatsupports the flask and imp
30、arts the motions necessary to themold making process.3.72 muller, nmachine 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
31、wheels (mullers) or both are mounted.3.73 nip point, npoint or zone in which a part of the bodycould be caught and squeezed between two surfaces, edges, orpoints.3.74 operators work zone(s), noperators work zone(s) ofequipment is that area in which the operators presence isrequired while operating i
32、n the intended manner.3.74.1 DiscussionAn employees presence applies to theentrance into the operators work zone of the employees bodyor any part thereof.3.75 pattern, nform of wood, metal, or other materialagainst which molding material is compacted to make a moldfor casting metals.3.76 pilot (flam
33、e or spark), nauxiliary source that ignitesthe main burner.3.77 pinch point, nzone in which a portion of the bodycould be caught and injured between surfaces, edges, or points.3.78 point of operation, nthat point or zone in which theprincipal operation is being performed.3.79 pouring, nfinal transfe
34、r of molten metal before itssolidification into its intended form.3.80 pouring area, nlocation in a foundry where moltenmetal is poured into molds or transferred from a ladle to afurnace.3.81 power off or out, nstate in which power cannot flowto the equipment from the source (see 4.4).3.82 power loc
35、ked 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 power disconnect, to a group lockoutdevice, group lockbox, or comparable mechanism.3.83 presence-sensing device, n
36、device designed, con-structed, and arranged to create a sensing field or area that willdetect either the presence or absence of personnel.3.84 protection from unexpected machine movement, nseeprotection, primary and protection, secondary.3.84.1 DiscussionThere are hazards other than unex-pected move
37、ment, and the OSHA machine lockout/tagoutstandard 29 CFR 1910.147 includes protection against suchother hazards.3.85 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
38、, or controlled. The state in which OSHA lockout/tagout has been established.3.85.1 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.3.86 protection, secondary, nlimi
39、ted protection by con-trol devices.3.86.1 DiscussionIt is possible for control devices, likelimit switches, to malfunction mechanically or electrically, andinterlocks intended for safety purposes are sometimes bypassedor wedged or tied in actuated states. Secondary protection isonly justifiable when
40、 there is no practical alternative, that is,when primary protection is not practical and when regulardisciplined maintenance is present. The operator, whose con-stant attitude should be one of caution, should understand thefact that operator protection devices such as interlocked guardsare secondary
41、 protection. Frequent inspections of such protec-tive devices should be made. Locking a STOP push button inE2349 125the actuated position instead of using OSHA lockout/tagout isan example of a dangerous attempt to use secondary protectionagainst machine movement.3.87 protective device, nmeans whereb
42、y personnel accessto a hazard zone or area is denied by other than a physicalguard.3.87.1 DiscussionProtective devices include, but are notlimited to, two-hand controls, two-hand trips, and hostagecontrols.3.88 puncture point, nzone in which a part of the bodycould be punctured or perforated.3.89 qu
43、alified 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.3.90 qualified person, nperson determined by the em-p
44、loyer to have the training or experience or both to operate ormaintain or both the equipment involved.3.91 reactive metal, nany metal that is readily oxidizedwith the release of large quantities of heat.3.92 runout pit, npit placed below or in front of a furnaceor both to receive molten material in
45、an emergency.3.93 safety, nstate of being reasonably free or reasonablyprotected from injury or risk. Never to be construed as absoluteor perfect protection from harm, injury, or risk.3.94 sand mixer, nmachine for conditioning mold andcore sand by controlled mixing with additives.3.95 sand muller, n
46、machine for conditioning mold andcore sand by controlled mixing with additives.3.96 sand system, nthat part of a foundry installation thatprocesses and transports sand or other media in bulk form.3.97 screen (sand), nsieve or riddle with openings ofdefinite size used to separate one grain size from
47、another or toremove lumps and foreign objects from sand.3.98 semiutomatic, adjat least one machine function inthe cycle is automatically performed and sequenced, but whichrequires the operator to initiate at least one function manually.3.99 semiautomatic mode, nmethod of operation in whichat least o
48、ne function in an equipment cycle requires manualinitiation and at least one function is automatically sequenced.3.100 shear pin, npin built into a mechanism designed tofail under specified loading and act as an overload disconnect.3.101 shear point, npoint or zone in which body partscould be caught
49、 by one machine member moving past another.3.102 shutdown, nplanned steps required to take machineor process out of operation.3.103 skimming, nremoving slag or dross from the sur-face of the molten metal.3.104 skip hoist, nbasket, bucket, or other container thatis drawn or elevated on rails by a pulling or pushing action.3.105 slag, nnonmetallic byproducts and contaminantsgenerated during the melting, transferring, and holding ofmolten metal.3.106 slag hole or door, nopening in the furnace throughwhich slag is removed.
