Gjuterier - produktionsprocessen

	Document name
		Gjuterier - produktionsprocessen
Area/location	Date
	Invalid Date
Approved by	Participants

Description	The list is based on the following regulations

Råmaterial

Question	Risk assessment:
	Low	Medium	High
1. Are raw materials stored in a way that protects them from moisture, oil, etc.? (Note: This reduces the risk of explosion during casting.)
2. Is moist raw material preheated or dried before it is melted?
3. When purchasing raw materials, you require that it is free of
a) Are there any hazardous substances such as lead compounds, paint residues, etc.?
b) Radioactive material?
4. Are the raw materials checked upon delivery?

Kärn- och formtillverkning

Question	Risk assessment:
	Low	Medium	High
5. Do binder hardeners need to be changed to another type, e.g. inorganic binders (water glass), which is better from a work environment point of view?
6. When working with organic binder systems (e.g. cold-box, hot-box, shell sand, furan, resol and ester)
a) Is the work carried out completely encapsulated and preferably in a secluded space?
b) Do the staff work with pneumatic masks throughout the work?
c) Is there a risk of skin contact with chemicals?
d) Are there handling and safety instructions?
7. Is there heavy work associated with portioning casting sand or preparing molds?
8. Is there a height-adjustable table, e.g. a lift table, for placing the molds when checking and polishing?
9. Is the mould shaped by hand without awkward working positions at the right height level? (Note: not on the floor.)
10. Are vacuum cleaners or central extractors used for sand removal? (Note: compressed air blowing or dry sweeping spreads dust.)

Blackning

Question	Risk assessment:
	Low	Medium	High
11. Are water-based inks used whenever possible?
12. Is alcohol blackening carried out under point extraction or in well-ventilated areas?
13. Are the spray gun and brushes cleaned in a ventilated gun wash?
14. Is compressed air avoided for cleaning the molds? (Note: Using compressed air spreads dust into the air.)

Ugnshall

Question	Risk assessment:
	Low	Medium	High
15. When loading raw materials into the furnace.
a) Is there a risk of burns during regular work or operational disruption?
b) Are there heavy and repetitive lifting?
c) Can the staff work at a suitable working height?
16. Is the oven thermally insulated and equipped with efficient extraction?
17. Is there ventilation available over the ovens?
18. Is heat radiation stressful for the furnace keeper?
19. Is any of the smoke from ovens causing discomfort?
20. Are personal protective equipment such as visors and aluminized protective clothing, safety shoes with toe caps, gaiters, helmets and protective gloves against heat radiation splashes made of molten material used?
21. The work schedule is designed to minimize the heat load as much as possible.
a) Increase in air movement in the room.
b) Slowing down the pace of work or increasing the break time.
c) Use of appropriate protective clothing.
22. Is the sideboard inspected regularly?
23. Are there procedures for laying brick sideboards?
24. Is the lifting beam for sideboard protected against heat radiation?
25. When transporting a ladle to and from the furnace
a) Is there a risk of burning?
b) Is there a risk of bumping into something when lifting the sideboard?
26. Is the knock-out done automatically?
27. Is indoor knockout carried out in a heated and well-ventilated room?
28. Is the mold and core sand removed from the casting without exposing the operator to excessive dust or loud noise?
29. Are the sand molds broken on shaking tables instead of being knocked apart by hand?
30. When reusing sand, is crushing, cooling, and sieving carried out encapsulated?
31. Can dry cleaning work be minimized by implementing design changes as early as possible in the production chain?
32. Can manual cleaning work be minimized?
a) With the help of, for example, manipulators, industrial robots or the like?
b) Through effective blast cleaning of the goods?
33. Does the workplace have a cleaning booth?
a) Is there good ventilation?
b) How can noise reduction be made more effective?
c) Good lighting with, for example, luminaires with protective glass.
d) Well-planned transportation to and from the workplace?
e) Suitable device for hanging tools?
f) Suitable handling equipment so that the work can be carried out in good working positions? Is there suitable handling equipment available to ensure that the work can be carried out in good working positions?
34. When working with hand-held cleaning machines, are there any specific ergonomic guidelines to follow?
a) Is there an extraction system on the hand sanders?
b) Does the sander have full blast protection?
c) Do grinders expose workers to unpleasant or harmful vibrations?
35. To prevent vibration injuries.
a) Are vibrating grinders used?
b) Has the balance of the grinding wheels been checked?
c) Is long-term work with a vibrating machine avoided?
36. Are lay-up tables or positioners used to place the goods in a suitable position?
37. Lift tables or tilt tables are used to minimize unnecessary bending when reaching for goods.
38. Are safety glasses with side protection available and used for activities such as grinding, drilling, and chiselling?
39. Is protective equipment stored in a plastic bag container in a separate box or cabinet to avoid contamination?
40. If the blasting machine vibrates excessively
a) Does it need to be covered inside with a rubber mat?
b) Does it need to stand on vibration-insulating material?
c) Does it need to be in a separate room?
41. Is there a dust leak during blasting or tumbling?
42. Are the drums equipped with spot ventilation?
43. Are measurements of dust from the foundry regularly conducted?
44. For example, are textile barrier filters required to be installed to reduce dust emissions?
45. Is hazardous waste stored under a roof on a hardened surface and without a floor drain?
46. Are there procedures for handling hazardous waste such as oils, etc.?
47. Is only an approved carrier used for the collection of hazardous waste, e.g. oil?
48. Is waste (e.g. packaging, batteries, etc.) sorted into different containers for recycling?
49. Are residents next door disturbed by noise from the foundry?

Other Here you can note risks that need to be addressed that are not included in the checklist

More checklists can be found at www.prevent.se/checklistor

Gjuterier - produktionsprocessen

General information about the checklist

Råmaterial (1-4)

Are raw materials stored in a way that protects them from moisture, oil, etc.? (Note: This reduces the risk of explosion during casting.)

Is moist raw material preheated or dried before it is melted?

When purchasing raw materials, you require that it is free of

a) Are there any hazardous substances such as lead compounds, paint residues, etc.?

b) Radioactive material?

Are the raw materials checked upon delivery?

Kärn- och formtillverkning (5-10)

Do binder hardeners need to be changed to another type, e.g. inorganic binders (water glass), which is better from a work environment point of view?

When working with organic binder systems (e.g. cold-box, hot-box, shell sand, furan, resol and ester)

a) Is the work carried out completely encapsulated and preferably in a secluded space?

b) Do the staff work with pneumatic masks throughout the work?

c) Is there a risk of skin contact with chemicals?

d) Are there handling and safety instructions?

Is there heavy work associated with portioning casting sand or preparing molds?

Is there a height-adjustable table, e.g. a lift table, for placing the molds when checking and polishing?

Is the mould shaped by hand without awkward working positions at the right height level? (Note: not on the floor.)

Are vacuum cleaners or central extractors used for sand removal? (Note: compressed air blowing or dry sweeping spreads dust.)

Blackning (11-14)

Are water-based inks used whenever possible?

Is alcohol blackening carried out under point extraction or in well-ventilated areas?

Are the spray gun and brushes cleaned in a ventilated gun wash?

Is compressed air avoided for cleaning the molds? (Note: Using compressed air spreads dust into the air.)

Ugnshall (15-49)

When loading raw materials into the furnace.

a) Is there a risk of burns during regular work or operational disruption?

b) Are there heavy and repetitive lifting?

c) Can the staff work at a suitable working height?

Is the oven thermally insulated and equipped with efficient extraction?

Is there ventilation available over the ovens?

Is heat radiation stressful for the furnace keeper?

Is any of the smoke from ovens causing discomfort?

Are personal protective equipment such as visors and aluminized protective clothing, safety shoes with toe caps, gaiters, helmets and protective gloves against heat radiation splashes made of molten material used?

The work schedule is designed to minimize the heat load as much as possible.

a) Increase in air movement in the room.

b) Slowing down the pace of work or increasing the break time.

c) Use of appropriate protective clothing.

Is the sideboard inspected regularly?

Are there procedures for laying brick sideboards?

Is the lifting beam for sideboard protected against heat radiation?

When transporting a ladle to and from the furnace

a) Is there a risk of burning?

b) Is there a risk of bumping into something when lifting the sideboard?

Is the knock-out done automatically?

Is indoor knockout carried out in a heated and well-ventilated room?

Is the mold and core sand removed from the casting without exposing the operator to excessive dust or loud noise?

Are the sand molds broken on shaking tables instead of being knocked apart by hand?

When reusing sand, is crushing, cooling, and sieving carried out encapsulated?

Can dry cleaning work be minimized by implementing design changes as early as possible in the production chain?

Can manual cleaning work be minimized?

a) With the help of, for example, manipulators, industrial robots or the like?

b) Through effective blast cleaning of the goods?

Does the workplace have a cleaning booth?

a) Is there good ventilation?

b) How can noise reduction be made more effective?

c) Good lighting with, for example, luminaires with protective glass.

d) Well-planned transportation to and from the workplace?

e) Suitable device for hanging tools?

f) Suitable handling equipment so that the work can be carried out in good working positions? Is there suitable handling equipment available to ensure that the work can be carried out in good working positions?

When working with hand-held cleaning machines, are there any specific ergonomic guidelines to follow?

a) Is there an extraction system on the hand sanders?

b) Does the sander have full blast protection?

c) Do grinders expose workers to unpleasant or harmful vibrations?

To prevent vibration injuries.

a) Are vibrating grinders used?

b) Has the balance of the grinding wheels been checked?

c) Is long-term work with a vibrating machine avoided?

Are lay-up tables or positioners used to place the goods in a suitable position?

Lift tables or tilt tables are used to minimize unnecessary bending when reaching for goods.

Are safety glasses with side protection available and used for activities such as grinding, drilling, and chiselling?

Is protective equipment stored in a plastic bag container in a separate box or cabinet to avoid contamination?

If the blasting machine vibrates excessively

a) Does it need to be covered inside with a rubber mat?

b) Does it need to stand on vibration-insulating material?

c) Does it need to be in a separate room?

Is there a dust leak during blasting or tumbling?

Are the drums equipped with spot ventilation?

Are measurements of dust from the foundry regularly conducted?