Product Overview

Summary: This Foundry Operations Safe Operating Procedure sets out a clear, step-by-step framework for running foundry processes safely, consistently and in line with Australian WHS requirements. It addresses the high‑risk nature of molten metal work, heavy plant, heat and fumes, helping you safeguard workers while maintaining production quality and uptime.

Foundry operations are among the highest-risk industrial activities, combining molten metals, extreme heat, heavy equipment, silica-based materials, mechanical handling and chemical binders. Without a robust, documented procedure, businesses face elevated risks of burns, fires, explosions, crush injuries, respiratory illness and environmental non-compliance. This Foundry Operations Safe Operating Procedure provides a structured, practical framework that integrates WHS obligations with day-to-day production realities in Australian foundries of all sizes.

The SOP guides users through each stage of the foundry process—from raw material receipt and charge preparation, through furnace operation, molten metal transfer and pouring, to shakeout, fettling, housekeeping and shutdown. It defines clear roles, minimum competency requirements, pre-start checks, PPE standards, hazard controls and emergency responses tailored to foundry environments. By implementing this SOP, businesses can standardise safe work practices across shifts and sites, improve incident prevention, support worker training and induction, and demonstrate due diligence under Australian WHS legislation and relevant standards.

Key Benefits

• Reduce the risk of burns, fires, explosions and crush injuries associated with molten metal and heavy foundry equipment.
• Ensure consistent compliance with Australian WHS legislation, relevant standards and industry best practice for high‑risk foundry work.
• Standardise operating practices across shifts and crews, improving product quality, throughput and operational reliability.
• Strengthen worker competence and confidence through clear instructions for start‑up, normal operation, upset conditions and shutdown.
• Improve audit readiness and regulatory defensibility with a documented, systematic approach to hazard identification and control in foundry operations.

Who is this for?

• Foundry Managers
• Production Supervisors
• WHS Managers
• Foundry Operators
• Melting Furnace Operators
• Moulding and Coremaking Technicians
• Maintenance Supervisors
• Health and Safety Representatives (HSRs)
• Operations Managers
• Training and Induction Coordinators

Hazards Addressed

• Exposure to molten metal, splashes and runouts leading to severe burns
• Fire and explosion risks from wet charge materials, combustible dusts and flammable coatings
• Extreme heat stress and heat-related illness in high-temperature work areas
• Crush and impact injuries from mould handling, ladles, cranes, hoists and mobile plant
• Inhalation of respirable crystalline silica, metal fumes and foundry dusts
• Noise-induced hearing loss from furnaces, shakeout, shot blasting and fettling operations
• Manual handling and musculoskeletal injuries from handling moulds, cores and castings
• Exposure to hazardous chemicals such as binders, resins, coatings and cleaning agents
• Slips, trips and falls due to poor housekeeping, spills and uneven surfaces
• Electrical hazards from furnaces, induction systems and associated control gear

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Description of Foundry Processes and Equipment
• 5.0 Hazard Identification and Risk Assessment for Foundry Operations
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre-Start Inspections and Area Preparation
• 8.0 Raw Material Handling and Charge Preparation
• 9.0 Furnace Operation (Start-Up, Normal Operation and Shutdown)
• 10.0 Molten Metal Handling, Ladling and Pouring Procedures
• 11.0 Moulding, Coremaking and Mould Assembly Controls
• 12.0 Shakeout, Fettling, Cleaning and Finishing Operations
• 13.0 Ventilation, Fume and Dust Control Measures
• 14.0 Manual Handling and Use of Cranes, Hoists and Mechanical Aids
• 15.0 Housekeeping, Waste Management and Spill Control
• 16.0 Lockout/Tagout and Maintenance Safety for Foundry Plant
• 17.0 Heat Stress Management and Fatigue Controls
• 18.0 Emergency Procedures (Burns, Fire, Explosion, Metal Runout and Spills)
• 19.0 Incident Reporting, Investigation and Corrective Actions
• 20.0 Training, Induction and Competency Verification
• 21.0 Monitoring, Review and Continuous Improvement

Legislation & References

• Model Work Health and Safety Act (as implemented in relevant Australian jurisdictions)
• Model Work Health and Safety Regulations (particularly Hazardous Work and Hazardous Chemicals)
• Safe Work Australia – Managing the Risks of Plant in the Workplace Code of Practice
• Safe Work Australia – Managing Noise and Preventing Hearing Loss at Work Code of Practice
• Safe Work Australia – Managing the Risk of Falls at Workplaces Code of Practice
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice
• Safe Work Australia – Managing the Risk of Heat in the Workplace (guidance material)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 2210 series: Occupational protective footwear
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 1269 series: Occupational noise management
• AS/NZS ISO 45001: Occupational health and safety management systems