Product Overview

This Foundry Work Safe Work Method Statement (SWMS) is a comprehensive safety planning document designed to identify hazards, assess risks and implement controls for all core foundry operations. It provides end-to-end coverage of multiple high-risk activities involved in foundry work, helping your business demonstrate due diligence and maintain strong WHS compliance.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Safe operation, inspection and isolation of arc furnace transformers during melting and refining processes
• Control measures for furnace operation tasks, including charging, tapping, temperature monitoring and slag removal
• Procedures for smelting plant operations, including feedstock handling, monitoring emissions and managing off-gas systems
• Safe pouring of molten metal, including pre-heating of ladles, controlled metal flow and maintaining exclusion zones
• Risk controls for lead casting tasks, including airborne lead exposure management, hygiene controls and medical monitoring
• Management of mould casting operations, including mould preparation, venting, drying and safe handling of hot moulds
• Controls for sand casting processes, including sand preparation, compaction, core setting and shakeout activities
• Casting shakeout, fettling and cleaning, including guarding of machinery, dust control and manual handling risk reduction
• Safe operation of furnaces and foundry equipment, including guarding, emergency stops, interlocks and lockout/tagout procedures
• Inspection, maintenance and repair of crucibles to minimise risk of failure, molten metal breakout and thermal shock
• Repair and maintenance of forging and foundry equipment, including isolation, permit-to-work and verification of zero energy
• Control of exposure to heat, noise, vibration, fumes and respirable dusts within foundry work areas
• Use of personal protective equipment (PPE) for molten metal work, including face shields, heat-resistant clothing and respiratory protection
• Housekeeping, spill control and management of refractory waste, slag and scrap metal storage areas
• Emergency response procedures for burns, fires, explosions and uncontrolled molten metal releases

Who is this for?

This SWMS is designed for foundries, metal casting and forging operations, smelting plants, maintenance contractors and site supervisors responsible for managing foundry work on Australian worksites.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Safe Work Australia – Foundry Code of Practice (where adopted by jurisdiction): Guidance on managing health and safety risks in foundry operations
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice: Controls for hazardous substances, fumes and lead exposure in foundries
• Safe Work Australia – Managing Noise and Preventing Hearing Loss at Work Code of Practice: Requirements for noise monitoring and control around furnaces and casting areas
• Safe Work Australia – Managing the Risk of Falls at Workplaces Code of Practice: Working around platforms, ladles and elevated furnace access
• Safe Work Australia – Managing the Work Environment and Facilities Code of Practice: Ventilation, temperature, amenities and emergency arrangements for hot work areas
• Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Risk management framework applied to all foundry activities
• Safe Work Australia – First Aid in the Workplace Code of Practice: First aid requirements for burns, heat stress and crush injuries
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment in foundry environments
• AS/NZS 1716: Respiratory protective devices performance requirements
• AS/NZS 2161: Occupational protective gloves for handling hot materials and sharp castings
• AS/NZS 1337.1: Eye and face protection for molten metal splash and grinding operations
• AS/NZS 1801: Occupational protective helmets for head protection in foundries
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017