BlueSafe

Foundry Work SWMS

This SWMS covers foundry work from pre-start planning and material preparation through melting, pouring, casting clean-up, maintenance and handover.

Activities covered include

  • Plan foundry work, access and work-area arrangements
  • Treat lead and alloy melts
  • Clean work areas, manage waste and complete handover

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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.

Foundry Work SWMS
  • 100% Compliant with Australian WHS Acts & Regulations
  • Fully Editable MS Word & PDF Formats Included
  • Pre-filled Content - Ready to Deploy Immediately
  • Customisable - Easily Add Your Logo & Site Details
  • Includes 2 Years of Free Compliance Updates

Product Overview

This SWMS covers foundry work from pre-start planning and material preparation through melting, pouring, casting clean-up, maintenance and handover. It supports the management of risks associated with molten metal, heat, dust, fumes, equipment, suspended loads and work-area conditions.

Activities & Specific Tasks Covered

This document includes task-specific risk controls for:

  • Plan foundry work, access and work-area arrangements
  • Receive and prepare charge materials
  • Prepare sand moulds and cores
  • Inspect furnaces, ladles and associated equipment
  • Operate the arc furnace transformer
  • Charge and smelt metal
  • Treat lead and alloy melts
  • Tap and pour molten metal
  • Cool, shake out and handle castings
  • Fettle and clean castings
  • Maintain crucibles and foundry equipment
  • Clean work areas, manage waste and complete handover

Who is this for?

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

Specific Job Steps & Hazards Covered

Job Step / Activity Potential Hazards
Pre-start planning and setup
  • Unauthorised access
  • Conflicting work activities
  • Molten-metal exposure
  • Mobile plant interaction
  • Poor emergency response
  • Inadequate worker competence
Receive and prepare charge
  • Explosion from wet scrap
  • Trapped gas in scrap
  • Falling scrap loads
  • Forklift collision
  • Manual handling strain
  • Oil and chemical contamination
Prepare sand moulds and cores
  • Respirable crystalline silica
  • Binder vapours
  • Chemical skin contact
  • Entanglement in mixers
  • Compressed-air injection
  • Manual handling strain
  • Dust ignition
Inspect furnace and ladle
  • Refractory failure
  • Molten-metal run-out
  • Ladle drop
  • Hydraulic failure
  • Gas release
  • Radiant heat
  • Electrical fault
Operate arc furnace transformer
  • Electric shock
  • Arc flash
  • Arc blast
  • Transformer fire
  • Unauthorised high-voltage access
  • Electromagnetic exposure
  • Toxic fume release
Charge and smelt metal
  • Molten-metal eruption
  • Metal fumes
  • Carbon monoxide exposure
  • Heat stress
  • Furnace overfill
  • Slag ejection
  • Noise exposure
Treat lead and alloy melts
  • Lead fume inhalation
  • Lead dust ingestion
  • Metal fume fever
  • Chemical splash
  • Molten-metal reaction
  • Contaminated work clothing
  • Take-home lead exposure
Tap and pour molten metal
  • Ladle failure
  • Molten-metal splash
  • Crush from suspended ladle
  • Mould explosion
  • Burns from radiant heat
  • Fume exposure
  • Fire from metal spill
Cool and shake out castings
  • Hot casting contact
  • Respirable silica dust
  • Phenolic resin fumes
  • Entanglement in conveyors
  • Falling castings
  • Machine vibration
  • Excessive noise
Fettle and clean castings
  • Flying metal fragments
  • Grinding-disc burst
  • Silica and metal dust
  • Abrasive-blasting exposure
  • Noise and vibration
  • Welding fumes
  • Fire and sparks
  • Electrical shock
Maintain crucibles and equipment
  • Stored energy release
  • Electric shock
  • Unexpected plant movement
  • Confined-space atmosphere
  • Silica dust from refractories
  • Falling objects
  • Hot surfaces
  • Crush during forging repair
Clean work areas and waste
  • Silica and lead dust
  • Hot waste
  • Slips and trips
  • Chemical spills
  • Fire from oily waste
  • Manual handling strain
  • Waste contamination
Demobilise and hand over
  • Uncontrolled plant restart
  • Residual hot surfaces
  • Incomplete isolation
  • Unreported equipment defects
  • Unauthorised access
  • Poor shift handover

Need to add specific site requirements?

Use the BlueSafe Portal to tailor this SWMS with site-specific details, job steps, hazards, controls and responsibilities before work starts.

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 includes references relevant to the documented work, including:

  • Applicable Commonwealth, state or territory WHS/OHS legislation and regulations.
  • Applicable hazardous chemicals, airborne contaminants, plant, electrical safety, noise, manual-task, confined-space, PPE, emergency-plan, consultation, training, health-monitoring and incident-notification duties under the relevant jurisdictional WHS/OHS framework.
  • Model Code of Practice: How to Manage Work Health and Safety Risks.
  • Model Code of Practice: Managing Risks of Plant in the Workplace.
  • Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace.
  • Model Code of Practice: Managing Noise and Preventing Hearing Loss at Work.
  • Model Code of Practice: Hazardous Manual Tasks.
  • Model Code of Practice: Managing Electrical Risks in the Workplace.
  • Model Code of Practice: Confined Spaces.
  • Model Code of Practice: Abrasive Blasting.
  • Foundry Code of Practice 2004, used as industry guidance for molten metal, furnace, dust, fume and foundry-process controls.
  • Metal Casting Compliance Code, used as industry guidance for hazardous substances, lead, molten metal, furnace maintenance, plant and cleaning controls.
  • AS/NZS 1715 Selection, use and maintenance of respiratory protective equipment.
  • AS/NZS 1716 Respiratory protective devices.
  • AS/NZS 1270 Acoustics—Hearing protectors.
  • AS/NZS 1337.1 Personal eye-protection equipment.
  • AS/NZS 2210.3 Personal protective equipment—Safety footwear.
  • AS 1657 Fixed platforms, walkways, stairways and ladders—Design, construction and installation.
  • AS/NZS 3000 Electrical installations (Wiring Rules).
  • AS/NZS 3760 In-service safety inspection and testing of electrical equipment.
  • AS 4024 series Safety of machinery.
  • AS 2550 series Cranes, hoists and winches—Safe use.

Standard SWMS Features (Click to Expand)
  • Task-specific job steps, hazards and control measures
  • Initial and residual risk ratings
  • Assigned responsible persons for each job step
  • Plant, equipment and PPE requirements where applicable
  • Permits, qualifications and high-risk construction work details where applicable
  • Worker consultation, sign-off and review sections

Suitable for Industries

Manufacturing and ProductionMetal Fabrication and WeldingMining and Resources

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