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Foundry control guidance sheet FD07 Dust when fettling smaller castings Control approach 2 Engineering control FD07 This guidance sheet is for employers to help them comply with the requirements of the Control of Substances Hazardous to Health Regulations 2002 (COSHH) by controlling exposure to chemicals and protecting workers' health. The sheet is part of HSE guidance COSHH essentials: easy steps to control chemicals. It describes the key points you need to follow to help reduce exposure to an adequate level. It is important to follow all the points, or use equally effective measures. Fettling sand-moulded castings creates silica dust and metal dusts that are hazardous to health. Crystalline silica can cause serious respiratory diseases including cancer. Consider shotblasting to remove sand residues. Control approach 2 (engineering control) is recommended to control dust from fettling smaller castings. You need also to control exposure to noise. Buy tools with low vibration ratings. Use them only for short periods to reduce hand-arm vibration syndrome (HAVS). Electrically powered hand held tools require portable appliance testing (PAT). For environmental advice see Further information on the back page. Access Restrict access to those staff who need to be there. Design and equipment Control fettlings and dust. Fettle small castings in a ventilated booth. Fettle very small castings using an abrasive or wire wheel fitted with local exhaust ventilation (LEV). You need an air speed between 1 and 2.5 metres per second into the fettling booth, or between 2.5 and 10 metres per second into pedestal grinder openings. Make sure a manometer or pressure gauge is fitted near the extraction point, to show that the extraction is working properly. Always confirm that the extraction is turned on and working at the start of work. Check the gauge. Discharge cleaned, extracted air to a safe place outside the building, away from doors, windows and air inlets. Have a supply of clean air coming into the workroom to replace extracted air. Position the workpiece so that it is as close as possible to the extraction point. Ensure that fettling dust is directed into the booth and that pneumatic tools do not blow dust out of the booth. Provide a turntable to move the casting. Consult a qualified ventilation engineer to design new control systems (see Control guidance sheet FD14). Maintenance Follow instructions in maintenance manuals. Keep equipment in effective and efficient working order. Repair faulty extraction systems immediately. Meanwhile, wear respiratory protective equipment (RPE). Fettlings are very abrasive and plant wears out quickly. Fettlings can block extraction points. Plan regular maintenance. Foundry control guidance sheet FD07 Examination and testing Look daily for signs of damage to the ducting, fan and air filter. Noisy or vibrating fans can indicate a problem. Repair damage immediately. At least once a week, check that the extraction system and gauge work properly. You need to know the manufacturer's performance specification to know if extraction is working properly. If this information isn't available, hire a competent ventilation engineer to determine its performance. The engineer's report must show the target air speeds. Keep this information in your testing logbook. Get a competent ventilation engineer to examine the system thoroughly and test its performance at least once every six months (see HSE publication HSG54). Keep records of all examinations and tests for at least five years. Review records to see if there are failure patterns that make planning maintenance easier. Cleaning and housekeeping Every day, clear up accumulations of dirt in those areas where people work all the time. Clean general workrooms once a week to stop dust being stirred up and to reduce slips. Use a Type H vacuum cleaner fitted with a HEPA filter to clear up dust. K Don't clean up with a brush or with compressed air. Personal protective equipment (PPE) Ask your safety-clothing supplier to help you get the right PPE. Respiratory protective equipment (RPE) is not normally needed for work done inside a fettling booth. RPE is needed for other fettling, for maintenance and cleaning, and for clearing up spills. Use a P3 standard of RPE (Assigned Protection Factor 20). Consult your supplier for advice. Replace RPE filters as recommended by your supplier. Throw away disposable masks after one use. Keep RPE clean and store it away from dust. Provide eye protection. Protective gloves are needed to help prevent injuries. Skin creams are important for skin protection and help in washing contamination from the skin. These are not 'barrier creams'. After work creams help to replace skin oils. K Never allow compressed air use for removing dust from clothing. K Workers must not take their coveralls home for washing. Use a contract laundry. Health surveillance Consider health surveillance for lung function and other health effects. Consult an occupational health professional (see Further information). Training Tell your workers that fettling dust can cause serious lung disease. Warn them also about hand-arm vibration and noise. Foundry control guidance sheet FD07 Provide health and safety training. Include supervisors and managers. Ensure training includes how to keep exposures low; how to check that the extraction system is working; how to use and look after PPE and RPE; and what to do if something goes wrong. Supervision Check that the extraction is working properly, PPE is being used properly, and the rules on personal hygiene are being followed. Ensure the health surveillance programme is being carried out for everyone that needs it. Ask your workers to check their skin for dryness or soreness every six months. If these effects appear, check the proper use of skin creams and PPE. Swap workers over if they need to use hand-held tools for long periods of time. Foundry control guidance sheet FD07 Further information Maintenance, examination and testing of local exhaust ventilation HSG54 (Second edition) HSE Books 1998 ISBN 0 7176 1485 9 An introduction to local exhaust ventilation HSG37 (Second edition) HSE Books 1993 ISBN 0 7176 1001 2 The selection, use and maintenance of respiratory protective equipment: A practical guide HSG53 (Second edition) HSE Books 1998 ISBN 0 7176 1537 5 Controlling airborne contaminants in the workplace Technical Guide TG7 British Occupational Hygiene Society 1987 ISBN 0 9059 2742 7 Health and safety consultants: the BOHS Faculty of Occupational Hygiene keeps lists of qualified hygienists who can help you. Contact BOHS on 0133 229 8087 or at www.bohs.org/ Occupational health professionals: details of doctors and nurses can be found in the Yellow Pages under 'Health and safety consultants' and 'Health authorities and services'. Also visit the NHS website at www.nhsplus.nhs.uk Depending on the scale of work, releases into the atmosphere may be regulated within the pollution prevention and control (PPC) framework. You should consult your local authority or the Environment Agency. In Scotland, consult the Scottish Environment Protection Agency (SEPA). They will advise you if PPC legislation applies to your company, and about air cleaning and discharging emissions into the air. Otherwise, minimise emissions into the air. Employee checklist I I Always follow the standard operating procedures. I I Is the extraction switched on and working properly? Check the gauge. Look for signs of leaks, wear and damage. I I If you find any problems, tell your supervisor. Don't just carry on working. I | Co-operate with health surveillance schemes. Use, maintain and store your PPE in accordance with instructions. Wash your hands before and after eating, drinking, smoking and using the lavatory. Never use solvents to clean your skin. Use skin creams provided as instructed. COSHH essentials: easy steps to control chemicals October 2003 Printed and published by the Health and Safety Executive