Product Overview

Summary: This Non-Ferrous Metals Processing Safe Operating Procedure sets out clear, step-by-step requirements for safely receiving, sorting, cutting, melting, alloying and handling non-ferrous metals in Australian workplaces. It helps businesses control high‑risk hazards such as molten metal, fumes, noise, mobile plant and manual handling while maintaining consistent product quality and WHS compliance.

Processing non-ferrous metals such as aluminium, copper, brass, bronze, lead and nickel alloys presents a unique combination of high temperatures, heavy equipment, hazardous fumes and complex material handling. Without a robust, documented procedure, businesses face increased risks of burns, fires, explosions, chemical exposure, environmental incidents and costly downtime. This Non-Ferrous Metals Processing SOP provides a structured, end-to-end framework that integrates WHS obligations into day-to-day operations, from raw material receipt and identification through to melting, alloying, casting, cooling, finishing and waste management.

Tailored for Australian foundries, smelters, recyclers and fabrication shops, the document translates regulatory requirements and industry best practice into practical, on-the-floor instructions. It clarifies roles and responsibilities, sets minimum controls for molten metal handling, ventilation, PPE, lockout/tagout and housekeeping, and establishes consistent operating parameters for furnaces and associated plant. By implementing this SOP, organisations can demonstrate due diligence, support worker training and competency, reduce incident rates, and protect both workers and the business from the serious consequences of uncontrolled non-ferrous metal processing activities.

Key Benefits

• Ensure safe, consistent handling of non-ferrous metals from receipt to finished product, reducing the likelihood of burns, fires and explosions.
• Reduce worker exposure to hazardous metal fumes, dusts and noise through clearly defined engineering, administrative and PPE controls.
• Demonstrate compliance with Australian WHS legislation and relevant standards, supporting audits, regulator inspections and customer requirements.
• Standardise processing parameters and workflows across shifts and sites, improving product quality, yield and operational efficiency.
• Support effective onboarding and refresher training for operators, supervisors and maintenance personnel with clear, task-specific instructions.

Who is this for?

• Foundry Managers
• Metallurgical Supervisors
• Production Managers
• WHS Managers and Advisors
• Non-Ferrous Furnace Operators
• Smelter and Refinery Operators
• Scrap Metal Yard Supervisors
• Maintenance Supervisors
• Health and Safety Representatives (HSRs)
• Operations Managers in Metal Recycling Facilities

Hazards Addressed

• Thermal burns from contact with molten metal, hot surfaces and splashes
• Fire and explosion risks from moisture in charge materials, combustible contaminants and furnace failures
• Exposure to hazardous metal fumes and dusts (e.g. aluminium, copper, lead, nickel and zinc compounds)
• Inhalation of fluxes, refractory dust and combustion by-products
• Crush and impact injuries from mobile plant, forklifts, overhead cranes and hoists
• Manual handling injuries from lifting, pushing and stacking ingots, scrap, moulds and refractory materials
• Eye injuries from molten metal splash, flying particles and intense light or glare
• Electrical hazards associated with induction furnaces, electric arc furnaces and ancillary equipment
• Noise-induced hearing loss from furnaces, fans, vibratory equipment and metal handling
• Slips, trips and falls due to poor housekeeping, spills of molten metal, slag or lubricants
• Chemical exposure from fluxes, coatings, release agents and cleaning chemicals
• Heat stress and dehydration in high-temperature processing areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Non-Ferrous Metals
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Plant, Equipment and Furnace Types Covered
• 6.0 Pre-Operation Requirements and Safety Checks
• 7.0 Raw Material Receipt, Identification and Segregation
• 8.0 Scrap Preparation, Cleaning and Moisture Control
• 9.0 Furnace Charging and Melting Procedures
• 10.0 Alloying, Fluxing and Temperature Control
• 11.0 Molten Metal Handling, Pouring and Casting
• 12.0 Cooling, Demoulding and Finishing Operations
• 13.0 Ventilation, Fume and Dust Control Measures
• 14.0 Personal Protective Equipment (PPE) Requirements
• 15.0 Control of Hazardous Chemicals and Lead-Containing Materials
• 16.0 Safe Use of Mobile Plant, Cranes and Lifting Equipment
• 17.0 Lockout/Tagout and Isolation for Maintenance and Cleaning
• 18.0 Housekeeping, Spill Management and Waste Disposal
• 19.0 Emergency Procedures for Burns, Fires and Explosions
• 20.0 Incident Reporting, Investigation and Corrective Actions
• 21.0 Training, Induction and Competency Assessment
• 22.0 Monitoring, Review and Continuous Improvement of the SOP

Legislation & References

• Model Work Health and Safety Act
• Model Work Health and Safety Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• 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 1337.1: Personal eye protection
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 45001 (ISO 45001): Occupational health and safety management systems
• AS 4024 series: Safety of machinery