Working in the primary metal industries can be a hazardous occupation. The making and shaping of iron, steel, aluminum, and other metals involves heat, pressure, the movement of molten metals, and other activities that can expose workers to numerous physical and chemical hazards. Heat, noise, radiation, vibration, airborne particles, space restrictions, hazards from falling objects, electrical shock, and molten metal are just a few examples of hazards that workers may be exposed to. And this is just the tip of the iceberg when it comes to potential hazards during the production of metals and metal casting.
This blog will review some of the more common hazards encountered during smelting and casting applications, as well as other activities associated with the primary metal industries.
What are Some of the Potential Hazards for Workers in Molten Metal Industries?
There are many potential hazards within the molten metal industries, including:
- Airborne chemical hazards – Chemicals in the workplace that workers are exposed to by inhalation.
- Noise – In smelting and casting, noise levels may quickly reach levels that may be hazardous and make it necessary to implement controls.
- Eye hazards and radiation – During smelting and casting activities there may be a risk of flying particles, sparks, and optical radiation.
- Falling objects – Due to the overhead hazards there is a real risk of being struck by falling objects or hitting your head on other objects.
- Heat and molten metal – Heat and molten metal are present throughout the metal production and casting process. Depending on how close workers are to the melt or furnace, additional protection including protective clothing may be needed to reduce exposure to radiant heat and molten metal splash.
What Production Processes are Involved in Heavy Manufacturing that Involves Molten Metals?
Before we get into the specific hazards, let’s take a high-level look at some of the production processes and associated hazards.
For steelmaking, the basic steps in the production process are coke production, iron making, steel making, refining, and casting. The hazards can include
- Potential respiratory hazards from metal dust and fume, combustion gases, and various contaminants generated during the coking process.
- Noise hazards from furnace operation and other activities, foreign body eye injuries as well as heat stress and radiant heat from molten iron and steel.
The basic steps of the aluminum production process are alumina production, anode production, aluminum smelting, and casting. The hazards can include:
- Potential respiratory hazards from alumina dust, fluorides, sulfur dioxide, and other contaminants that are generated during the smelting and anode production process.
- Noise hazards from furnace operation and other activities, foreign body eye injuries as well as well heat stress, and radiant heat from molten aluminum.
Foundry processes can vary depending on the metals and alloys used, and the type and size of castings produced. In general, the primary steps include mold and core making, melting and casting, shake-out/knock-out, and finishing and fettling. The hazards can include:
- Heat stress and radiant heat from the handling and pouring of molten metals.
- Inhalation of respirable crystalline silica, metal fume, and gases and vapors from fluxes, binders, release agents, and other additives.
- Noise hazards.