Name: Foundry Work Risk Assessment
Brand: BlueSafe Online
SKU: prod_01KBY6JPG934QTRN288WNFGEHC
Price: 79.50 AUD
Availability: InStock

Product Overview

This risk assessment covers foundry work activities from pre-start setup and material handling through melting, pouring, casting work, cleaning and maintenance. It supports identifying heat, molten metal, dust, chemical, plant and access hazards when planning controls and managing risks.

Activities & Risks Covered

This assessment addresses activities and risks including:

Set up work areas and complete pre-start checks
Handle scrap, alloys and charge materials
Operate furnaces and carry out melting work
Tap, ladle and transfer molten metal
Prepare moulds, cores and sand materials
Carry out pouring, cooling and cast floor work
Complete shakeout, knockout and casting cleaning
Undertake fettling, grinding, blasting, cutting and welding
Manage hazardous chemicals, gases and spills
Perform maintenance, relining and confined access work

Who is this for?

Suitable for contractors, workers, supervisors and businesses carrying out foundry work activities.

Activities & Hazards Covered

Activity	Potential Hazards
Work area setup and pre-start checks	Unauthorised entry to furnace, pouring or hot work areas Poor housekeeping causing slips, trips and delayed evacuation Inadequate communication of changing conditions, plant status or exclusions Visitors or workers with medical implants entering induction furnace areas
Scrap, alloys and charge material handling	Explosion or molten metal ejection from wet, sealed or contaminated scrap Manual handling strains during loading and sorting Cuts from sharp scrap edges Vehicle or forklift interaction in scrap handling areas
Furnace operation and melting	Exposure to carbon monoxide, metal fumes and other toxic gases Burns from radiant heat, hot surfaces and molten metal Noise exposure Electrical hazards near furnace systems
Tapping, ladling and molten metal transfer	Molten metal splash, runout or uncontrolled discharge Explosion from water or damp tools, ladles or mould contact Crush injuries from ladles, cranes or transfer equipment Eye injury from sparks, infrared and ultraviolet radiation
Moulding, core making and sand handling	Respirable crystalline silica exposure from sand handling and preparation Exposure to resins, binders, catalysts and other hazardous chemicals Dust buildup reducing visibility and contaminating adjacent work areas Manual handling and entanglement around mixers, conveyors or sand plant
Pouring, cooling and cast floor operations	Exposure to combustion gases, smoke and decomposition products from moulds and binders Burns from hot moulds, hot castings and radiant heat Struck by moving ladles, conveyors or overhead handling equipment Slips, trips and falls on uneven, sandy or obstructed surfaces
Shakeout, knockout and casting cleaning	Respirable silica dust, phenolic resin contaminants and airborne particulates Noise and vibration from knockout equipment Contact with hot castings and falling objects Entanglement or trapping in moving machinery
Fettling, grinding, blasting, cutting and welding	Flying fragments, disintegrating discs and metal dust Respirable crystalline silica, inhalable metal dust and fumes Arc flash, ozone, heat and fire from cutting or welding Noise, vibration and hazardous manual tasks
Hazardous chemicals, gases and spill response	Inhalation or skin exposure to hazardous chemicals such as resins, coatings, amines and solvents Fire or explosion from flammable or combustible substances Uncontrolled spills creating exposure, slip hazards or incompatible reactions Missing or outdated safety data information
Maintenance, relining and confined access work	Silica and refractory dust during knock-out and relining Confined space hazards including poor atmosphere, restricted access and heat Unexpected energisation or movement of plant during maintenance Falls, awkward postures and dropped objects during access work

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
Model guidance: Model Code of Practice: Managing risks of hazardous chemicals in the workplace — 2.1 How to identify which chemicals are hazardous; p. 15.
Model guidance: Model Code of Practice: Managing noise and preventing hearing loss at work — 5. Controlling the risks; p. 29.
Model guidance: Model Code of Practice: Managing the work environment and facilities — 2. The work environment; p. 13.
Model guidance: Model Code of Practice: Managing risks of plant in the workplace — 4.1 Guarding plant; p. 39.
Model guidance: Model Code of Practice: Confined spaces — 3.4 Assessing the risks; p. 24.
Model guidance: Model Code of Practice: Welding processes — 1.3 What is involved in managing risks associated with welding processes?; p. 10.
Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
Model guidance: Model Code of Practice: How to manage work health and safety risks — 3. Step 2 — How to assess risks; p. 15.
Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 2.1 Identifying the hazards; p. 14.

Standard Risk Assessment Features (Click to Expand)

Activity-specific hazard identification and control measures
Initial and residual risk ratings
Assigned responsible persons for each activity
Risk matrix and assessment classification
Review, monitoring and sign-off fields
Site-specific customisation before use

Foundry Work Risk Assessment

Activities covered include

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Acceptance guaranteed