SMELTERS
AND FOUNDRIES
The smelting and foundry industry is a vital part of the metal industry and plays a key role in the production of everything from construction materials to advanced components for the automotive and technology sectors. In these operations, metals such as iron, zinc, aluminium and steel are melted at extremely high temperatures and then shaped by casting them into different types of moulds.
These processes require advanced technology, precise control and a high level of expertise, while also involving significant risks to both workers and the environment. To protect against hazards such as radiant heat and molten metal splashes, certified flame retardant protective clothing that meets EN ISO 11612 is required. Depending on the metal or mineral being processed, the protective clothing must also be certified with the appropriate code letter.
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RISK ASSESSMENT METALLURGY
- This is what you get when you download the guide:
- Review of the different steps for carrying out a risk assessment within metallurgy. Suggestions for protective clothing adapted for working with different types of metals and minerals.
RISKS WHEN WORKING IN SMELTERS AND FOUNDRIES
Work in smelters and foundries involves several serious risks because the operations are based on the handling of molten metal, high temperatures and heavy processes. One of the most obvious risks is burns. Molten metal can reach temperatures of over 1,500 degrees, and even small splashes can cause very severe injuries. Accidents can occur during casting, tapping or if moisture comes into contact with molten metal, which can lead to explosive reactions.
Another major risk is exposure to hazardous substances. During melting and casting, fumes, gases and dust are generated that may contain metal particles and chemicals. Inhaling these can damage the respiratory tract and in the long term lead to chronic diseases. Poor ventilation or insufficient use of respiratory protection significantly increases this risk.
Heavy lifting and working with large components also involves a risk of strain injuries and acute accidents, such as crush injuries. Machines, conveyor belts and lifting equipment can be dangerous if they are not used correctly or if safeguards are missing. Falls can occur, especially in environments with slippery floors, differences in levels or confined spaces.
Noise is another factor that can negatively affect health. Prolonged exposure to high noise levels can lead to hearing damage. In addition, the hot and often stressful working environment can cause fatigue, which in turn increases the risk of mistakes and accidents.
Workers in smelters and foundries usually need protective clothing in PPE category III because the temperatures are extremely high and there is a risk of being exposed to molten metal. To avoid injuries, flame-retardant clothing that meets EN ISO 11612 is required and, depending on which metal or mineral is used, the protective clothing must also be certified with the correct code letter.
How to conduct a risk assessment
How to choose the right protective clothing
RISK ASSESSMENT
Common risks when working with molten metals
SPLASHES OF MOLTEN METAL
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Molten metal
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Flame and heat
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Heat stress
When working with molten metal, protective clothing in PPE category III is usually required, as the temperatures are extremely high and there is a risk of being splashed with molten metal. To avoid injuries, flame retardant garments that comply with EN ISO 11612 are required. In these environments, there is also a risk of suffering from heat stress. Therefore, a Tranemo Skinsafe™ system with 2 or 3 layers is recommended, which insulates against radiant heat and increases protection thanks to the air gaps between the different layers protecting the wearer from heat and energy.
Flame and heat
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Flame spread
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Convective heat
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Radiant heat
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Contact heat
For work where there is a risk that garments may come into contact with heat and flame, flame retardant workwear is required. Protection against flame and heat is the basic protection in all Tranemo flame retardant garments. In a complete protection system, the protective clothing must cover the neck, torso, arms and legs; either with a full-covering garment such as an overall, or a two-piece system with, for example, jacket and trousers, with the same certification.
WELDING
- Welding sparks
- UV radiation
- Flame and heat
- Heat stress
During welding work, the worker is exposed to welding sparks, intense heat and harmful UV radiation. To reduce the risk of burns and heat stress, the correct welding clothing must be used, certified and adapted to both the welding technique and the working environment. Work with heavy welding in tough environments requires the use of flame retardant clothing certified according to EN ISO 11612 in combination with welding protection EN ISO 11611 class 2. The welding standard partly governs how the welding clothing is designed, since welding sparks must not stick to the clothes or in open pockets.
During welding, a lot of UV and heat radiation is generated. To increase the user’s comfort and avoid heat stress, Tranemo has therefore added ventilation openings to collections suitable for welding. To insulate against the heat radiation and to increase protection, a Tranemo Skinsafe™ system in two or three layers is recommended.
class="btn btn--secondary">Read about the welding standard EN ISO 11611
ELECTRIC Arc flash
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Radiant heat
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Convective heat
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Electric shock
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Shock wave
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Loud noise
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Optical radiation
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Toxic gas
Working with electricity is risky and means that the worker is constantly exposed to different types of hazards. A short circuit or other problems can cause a powerful arc flash which often has devastating consequences if the correct protective clothing is not used. The arc flash challenges the flame retardant garments with, for example, radiant heat, metal splashes and optical radiation, which also requires the user to wear protective clothing from top to toe and from the inside out.
An arc flash can be very powerful and affects the worker and the protective clothing in different ways. By using a Tranemo Skinsafe™ system where the outer layer has PPE 2 with ELIM above 8 cal/cm², the effects of these hazards are minimised. All Tranemo’s arc flash certified garments have the Arc Rating value indicated on the outside of the garments to make it easy to choose the right protection.
TRAFFIC
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Collision accidents
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Crush injuries
It is very important to be clearly visible when working close to traffic, or in environments with moving processes such as overhead cranes or forklifts. In environments like these, high-visibility protective clothing certified according to EN ISO 20471 is often a requirement. The fluorescent fabric of the garments ensures that you are clearly visible during the day, while the reflective tape makes you visible when darkness falls. Since collision accidents are among the most common workplace accidents, high visibility is included in most of Tranemo’s outer garments.
class="btn btn--secondary">Read about the high-visibility standard EN ISO 20471
WORKING WITH DIFFERENT METALS
Iron and steel
When you work with molten iron or steel, you need garments certified according to EN ISO 11612 E1-E3, where E3 is the highest level. If the fabric withstands molten iron and the metal does not stick to the surface, the fabric will usually also cope with molten copper, molten phosphor bronze and molten brass.
Aluminium
When you work with molten aluminium, you need garments certified according to EN ISO 11612 D1-D3, where D3 is the highest level. If the fabric withstands molten aluminium and the metal does not stick to the surface, the fabric will usually also cope with molten aluminium bronze and molten minerals.
Zinc
Zinc challenges protective clothing in a very special way because zinc sticks to most fabrics. Tranemo's Apex collection has an outer layer of aramid that does not break up even if the zinc sticks to the fabric. To block radiant heat and increase protection, Apex also has double fabric at the front of the jacket and trousers. When you work with molten zinc, you need garments that are certified according to EN ISO 11612, made from a fabric with a higher degradation temperature than 420°C (the melting point of zinc).
Other metals
Other molten metals and alloys have different melting points, viscosities and production processes that challenge protective clothing in different ways. If you work with other molten metals, contact Tranemo to find the right solution for your specific operation.
FIND THE RIGHT PROTECTIVE CLOTHING FOR SMELTERS AND FOUNDRIES
RECOMMENDED RANGE FOR WORK IN SMELTERS AND FOUNDRIES
OUR STRENGTHS in smelters and foundries
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