Product Overview

Summary: This Metal Casting Safe Operating Procedure sets out a clear, step-by-step method for carrying out foundry and metal casting work safely, consistently and in line with Australian WHS requirements. It helps control the extreme risks associated with molten metal, high temperatures and fumes, while improving product quality and operational efficiency across your casting operations.

Metal casting presents some of the highest-risk conditions in manufacturing: molten metal at extreme temperatures, heavy moulds and equipment, airborne contaminants and confined working areas. Without a robust, documented procedure, businesses face an elevated likelihood of burns, fires, explosions, manual handling injuries and long-term health impacts from fumes and dust. This Metal Casting Safe Operating Procedure provides a structured, WHS-aligned framework that guides workers through every stage of the casting process, from pre-start inspections and mould preparation through to pouring, cooling, fettling and clean-up.

Developed specifically for Australian workplaces, this SOP helps you translate WHS obligations into practical on-the-floor controls that operators can actually follow. It clarifies responsibilities, standardises PPE and equipment checks, embeds lock-out/tag-out practices, and sets minimum controls for ventilation, housekeeping and emergency response. By implementing this procedure, you not only reduce the likelihood of serious incidents but also achieve more consistent cast quality, less rework and clearer training pathways for new and existing staff. The result is a safer, more compliant and more efficient foundry environment that can withstand regulatory scrutiny and support sustainable business growth.

Key Benefits

• Reduce the risk of burns, fires and explosions associated with molten metal handling.
• Ensure consistent compliance with Australian WHS legislation and relevant standards in foundry operations.
• Standardise metal casting steps to improve product quality and reduce scrap and rework.
• Strengthen induction and refresher training with a clear, visual procedure operators can follow.
• Minimise unplanned downtime by embedding pre-start checks, equipment maintenance and housekeeping controls.

Who is this for?

• Foundry Supervisors
• Metal Casting Operators
• Pattern Makers
• Maintenance Technicians
• WHS Managers
• Production Managers
• Workshop Managers
• Health and Safety Representatives (HSRs)
• Manufacturing Engineers
• Apprentice Foundry Workers

Hazards Addressed

• Exposure to molten metal and splashes causing serious burns
• Fire and explosion risks from moisture in moulds, charge materials or tools
• Inhalation of metal fumes, foundry dust and combustion products
• Heat stress and dehydration from working near furnaces and hot surfaces
• Manual handling injuries from lifting and moving moulds, cores and castings
• Crush and pinch injuries from handling ladles, tongs and mechanical handling equipment
• Eye injuries from sparks, slag and flying debris during fettling and cleaning
• Slips, trips and falls due to spilt metal, sand, slag and poor housekeeping
• Electrical hazards from furnaces, induction equipment and associated control panels
• Noise-induced hearing loss from grinding, fettling and mechanical equipment

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Operators, Visitors)
• 4.0 Required Competencies, Licences and Training
• 5.0 Plant, Equipment and Materials Used in Metal Casting
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Hazard Identification and Risk Controls for Metal Casting
• 8.0 Pre-Start Checks and Work Area Preparation
• 9.0 Furnace Operation and Charge Preparation
• 10.0 Mould and Core Preparation and Inspection
• 11.0 Ladle Preparation, Preheating and Handling
• 12.0 Metal Pouring Procedure (Including Communication and Signalling)
• 13.0 Cooling, Shakeout and Handling of Hot Castings
• 14.0 Fettling, Grinding and Finishing Controls
• 15.0 Ventilation, Fume and Dust Control Measures
• 16.0 Housekeeping and Waste Management (Slag, Sand, Offcuts)
• 17.0 Lock-Out/Tag-Out and Isolation Procedures for Maintenance
• 18.0 Emergency Procedures (Burns, Fire, Explosion, Spills, Power Failure)
• 19.0 Incident Reporting, Investigation and Corrective Actions
• 20.0 Inspection, Monitoring and Review of the SOP
• 21.0 Recordkeeping, Training Logs and Competency Assessments

Legislation & References

• Model Work Health and Safety Act 2011 (Cth) and Regulations
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Code of Practice: Managing the risk of falls at workplaces
• Safe Work Australia – Code of Practice: Managing noise and preventing hearing loss at work
• Safe Work Australia – Code of Practice: Managing the work environment and facilities
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161: Occupational protective gloves (series)
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 4501.2: Occupational protective clothing – General requirements
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use