Schedule XXX

OPERATIONS IN FOUNDARIES, FURNACES & INDUCTION

FURNACES

1. Application

Provisions of this schedule shall apply to all parts of factories where any

of the following operations or process are carried on:

(a) The production of iron casting or, as the case may be, steel castings by

casting in moulds made of sand, loam, moulding composition or other

mixture of materials, or by shell moulding or by centrifugal casting and any

process incidental to such production;

(b) the production of non-ferrous castings by casting metal in moulds made of

sand, loam, metal, moulding composition or other material or mixture or

materials, or by shell mouldings, die-casting (including pressure die-

casting), centrifugal casting or continuous casting and any process

incidental to such production ;

(c) the melting and casting of non-ferrous metal land/or ferrous metal) for the

production of ingots, billets, slabs or other similar products and the

stripping thereof; but shall not apply with respect to

(i) any process with respect to the smelting and manufacture of lead and

the Electric Accumulators ;

(ii) any process for the purposes of printing works; or

(iii) any smelting process inwhich metals obtained by a reducing operation

or any process incidental to such operation ; or

(iv) any process in the course of the manufacture of solder or any process

incidental to such manufacture; or

(v) the melting and casting of lead or any lead-based alloy for the

production of ingots, billets, slabs or other similar products or the

stripping thereof, or any process incidental to such melting, casting or

stripping.

2. Definition

For the purpose of this Schedule

(i) "approved respirator” means a respirator of a type approved by the

Chief Inspector-cum-Facilitator ;

(ii) "Cupola or furnace" includes a receiver associated therewith;

(iii) "dressing or fettling operations" includes stripping and other removal of

adherent sand, corers, runners, risers, flash and other surplus metal

froma casting and the production of reasonably clean and smooth

surface, but does not include

a. the removal of metal from a casting when performed incidentally in

connection with the machining or assembling of castings after they

have been dressed or fettled, or

b. any operation which is a knockout operation within the meaning of

this Schedule ;

(iv) "foundry" means those parts of a factory in which the production of

iron or steel or non-ferrous castings (not being the production of pig

iron or the production of steel in the form of ingots) is carried on by

casting in moulds made of sand, loam, moulding composition or other

mixture of materials, or by steel moulding or by centrifugal casting in

metal moulds lined with sand, or die casting including pressure die

castings, together with any part of the factory in which any of the

following processes arc carried on as incidental processes in

connection with and in the course of, such production, namely, the

preparation and mixing of materials used in foundry process, the

preparation of moulds and cores, knock-out operations and dressing

or fettling operations ;

(v) "knock-out operations" means all methods of removing castings from

moulds and the following operations, when done in connection

therewith, namely, stripping, coring out and the removal of runners

and risers ;

(vi) "pouring aisle" means an aisle leading from a main gangway or

directly from a cupola or furnace to where metal is poured into

moulds.

(vii) “qualified supervisors” means a person possessing a Bachelor’s

Degreein Science or Diploma or Degree in Engineering with Certificate

in ferrous/non-ferrous technology from any institution recognized by

the Chief Inspector-cum-Facilitator.

3. Prohibition of use of certain materials as parting materials

(1) A material shall not be used as a parting material if it is a material

containing compounds of silica calculated as silica to the extent more than

five per cent, by weight of the dry material:

Provided that this prohibition shall not prevent the following being

used as a parting material if the material does not contain an admixture of

any other silica:

(i) Zirconium silicate (zircon).

(ii) Calcinedchina clay.

(iii) Calcinedaluminious fireclay.

(iv) Sillimanite.

(v) Calcinedorf used alumina.

(vi) Olivine.

(vii) Natural sand.

(2) Dust or other matter deposited from a fettling or blasting process shall not

be used as a parting material or as a constituent in a parting material.

4. Arrangement and storage

For the purposes of promoting safety and cleanliness in workrooms, the

following requirements shall be observed:

(a) moulding boxes, loamplates, ladles, patterns, pattern plates, frames,

boards, box weights, and other heavy articles shall be so arranged and

placed as to enable work to be carried on without unnecessary risk ;

(b) suitable and conveniently accessible racks, bins or other receptacles

shall be provided and used for the storage of other gear and tools;

(c) where there is bulk storage of sand, fuel, metal scrap or other materials

or residues, suitable bins, bunkers or other receptacles shall be provided

for the purpose of such storage.

5. Construction, Installation and Operation

(1) The precinct in which induction furnace is installed shall be of adequate

strength and shall be segregated from the other parts of the factory in

such a way so that minimum number of workers is exposed to the risk of

any fire or explosion at any time;

(2) Furnace shed shall be well ventilated

(3) All the fitting and attachment of Induction furnace shall be of good

construction, sound material and adequate strength;

(4) Adequate arrangements shall be made to avoid tilting of the ladles while

transportation

(5) Ladle shall not be filled with molten metal more than 3/4th of its volume

to avoid spillage of molten metal while being carried by the crane;

(6) The refractory material of the induction furnace shall be strong at high

temperature, resistant to thermal shock, chemically inert, low thermal

conductivity and co-efficient of expansion and of adequate uniform

thickness.

(7) The lining of the induction furnace shall be checked by qualified

supervisor every week for any wear and tear and damage as per

relevant Bureau of Indian Standards.

(8) Adequate precautions shall be taken during repair of induction furnace

as per relevant bureau of Indian Standards.

6. Construction of floors

(1) Floors or indoor work places in which the processes are carried on,

other than parts which are of sand, shall have an even surface of hard

material.

(2) No part of the floor of any such indoor work place shall be of sand

except, where this is necessary by reason of the work done.

(3) All parts of the surface of the floor of any such indoor work place which

are of sand shall, so far as practicable, be maintained in an even and

firm condition.

7. Means of escape

There shall be at least two ways of escape with adequate width at opposite

ends of the furnace platforms.

8. Display of Notice

Notice regarding non-use of water, etc. near induction furnace shall be

displayed

9. Charging of scrap in Induction Furnace

(1) No scrap material with close cavities shall be charged in the induction

furnace. Scrap to be charged shall be dry and shall not contain oil or

any other liquid or moisture.

(2) No scrap material shall be fed into induction furnace unless it is

thoroughly checked in the presence of qualified Supervisor.

(3) Sealed container or part made by centrifugal casting shall not be fed into

the furnace unless it is cut into pieces.

(4) No worker shall be engaged in charging of scrap material in induction

furnace unless practical measures such as substantial safeguards against

splash of hot metal, splatter etc., are provided.

(5) Scrap received in the form of pressed bundle should be opened, sorted

and only then fed into furnace.

10. Cleanliness of Indoor workplaces

(1) All accessible parts of the walls of every indoor workplace in which the

processes are carried on and of everything affixed to those wall shall be

effectively cleaned by a suitable method to a height of not less than 4.2

meters from the floor at least once in every period of fourteen months.

A record of the carrying out of every such effective cleaning in

pursuance of this paragraph including the date (which shall be not less

than five months nor more than nine months after the last immediately

preceding washing, cleaning or other treatment).

(2) Effective cleaning by a suitable method shall be carried out atleast once

every working day of all accessible parts of the floor of every indoor

workplace in which the processes arc carried on, other than pans which

are of sand; and the parts which are of sand shall be kept in good

order.

11. Manual operations Involving molten metal

(1) There shall be provided and properly maintained for all persons

employed on manual operations involving molten metal with which they

are liable to be splashed, a working space for that operation

(a) Which is adequate for the safe performance of the work and

(b) which, so far as reasonably practicable, is kept free from

obstruction.

(2) Any operation involving the carrying by hand of a container holding

molten metal shall be performed on a floor all parts of which were any

person walks while engaged in the operation shall be on the same level

:

Provided that, where necessary to enable the operation to be per-

formed without undue risk, nothing in this paragraph shall prevent the

occasional or exceptional use of a working space on a different level

from the floor, being a space provided with a safe means of access

from the floor for any person while engaged in the operation.

12. Gangways and pouring aisles

(1) In every workroom to which this paragraph applies constructed,

reconstructed or converted for use as such after the making of this

schedule and, so far as reasonably practicable, in every other

workroom to which this paragraph applies, sufficient and dearly defined

main gangways shall be provided and properly maintained which

(a) shall have an even surface of hard material and shall, in particular,

not be of sand or have on them more sand than is necessary to

avoid risk of flying metal from accidental spillage ;

(b) shall be kept, so far as reasonably practicable, free from

obstruction;

(c) if not used for carrying molten metal, shall be atleast 920

millimeters in width ;

(d) if used for carrying molten metal shall be

i. Where truck ladles are used exclusively, atleast 600 millimeters

wider than the overall width of the ladle;

ii. Where hands hanks are carried by not more than two men, at least

920 millimeters in width ;

iii. Where hands hanks are carried by more than two men, at least 1.2

meters in width; and

iv. Where used for simultaneous travel in both directions by men

carrying hands hanks, atleast 1.8 meters in width.

(2) In workroom to which this paragraph applies constructed, reconstructed

or converted for use as such after the making of this Schedule, sufficient

and clearly defined pouring aisles shall be provided and properly

maintained which

(a) shall have an even surface of hard material and shall, in particular,

not be of sand or have on them more sand than is necessary to avoid

risk of flying metal from accidental spillage;

(b) shall be kept so far as reasonably practicable free from obstruction;

(c) if molten metal is carried in hand ladles or bull ladles by not more

than two men per ladle, shall be atleast 460 millimeters wide, but

where any moulds along side the aisle arc more than 510 millimeters

above the floor of the aisle, the aisle shall be not less than 600

millimeters wide;

(d) if molten metal is carried in hand ladles or bull ladles by more than

two men per ladle, shall be atleast 760 millimeters wide ;

(e) if molten metal is carried in crane, trolley or truck ladles, shall be of a

width adequate for the safe performance of the work.

(3) Requirements of sub-paragraphs (1) and (2) shall not apply to any

workroom or part of a workroom if, by reason of the nature of the work

done therein, the floor of that workroom or, as the case may be, that

part of a workroom has to be of sand.

(4) In this paragraph" work room to which this paragraph applies" means a

part of a ferrous or non-ferrous foundry in which molten metal is

transported or used, and a work room to which this paragraph applies

shall be deemed for the purposes of this paragraph to have been

constructed, reconstructed or converted for use as such after the making

of this schedule if the construction, reconstruction or conversion thereof

was begun after the making of this Schedule.

13. Work near cupolas and furnaces

No person shall carry out any work within a distance of four meters from a

vertical line passing through the delivery and of any spout of a cupola or

furnace, being a spout used for delivering molten metal, or within a

distance of 2.4 meters from a vertical line passing through the nearest part

of any ladle which is in position at the end of such as pout, except in either

case where it is necessary for the proper use or maintenance of a cupola or

furnace that work should be carried out within that distance of that work is

being carried out at such a time and under such conditions that there is no

danger to the person carrying it out from molten metal which is being

obtained from the cupola or furnace or is in a ladle in position at the end of

the spout.

14. Dust and fumes

(1) Open coal, coke or wood fires shall not be used for heating or drying

ladles inside a workroom unless adequate measures are taken to prevent,

so far as practicable, fumes or other impurities from entering into or

remaining in the atmosphere of the workroom.

(2) No open coal, coke or wood fires shall be used for drying moulds except

in circumstances in which the use of such fires is un-avoidable.

(3) Mould stoves, core stoves and annealing furnaces shall be so designed,

constructed, maintained and worked as to prevent, so far as practicable,

offensive or injurious fumes from entering into any workroom during any

period when a person is employed therein

(4) All knock-out operations shall be carried out

(a) In a separate part of the foundry suitably partitioned off, being a room

or partin which, so far as reasonably practicable, effective and suitable

local exhaust ventilation and a high standard of general ventilation are

provided ; or

(b) In an area of the foundry in which, so far as reasonably practicable,

effective and suitable local exhaust ventilation is provided, or where

compliance with this requirement is not reasonably practicable, a high

standard of general ventilation is provided.

(5) All dressing or fettling operations shall be carried out

(a) in a separate room or in a separate part of the foundry suitably

partitioned off ; or

(b) in an area of the foundry set apart for the purpose ; and shall, so far as

reasonably practicable, be carried out with effective and suitable local

exhaust ventilation or other equally effective means of suppressing

dust, operating as near as possible to the point of origin of the dust.

15. Maintenance and examination of exhaust plant

(1) All ventilating plant used for the purpose of extracting, suppressing or

controlling dust or fumes shall be properly maintained.

(2) All ventilation plant used for the purpose of extracting, suppressing or

controlling dust or fumes shall be examined and inspected once every

week by a responsible person. This shall be thoroughly examined and

tested by a competent person atleast once in every period of twelve

months; and particulars of the results of every such examination and

test shall be entered in a register in Form XX, which shall be kept readily

available for inspection by an Inspector-cum-Facilitator. Any defect

found on any such examination and test shall be immediately reported in

writing by the person carrying out the examination and test to the

Occupier of the Factory.

16. Protective equipment

(1) The occupier shall provide and maintain suitable protective equipment

specified for the protection of workers,

(a) Suitable gloves or other protection for the hands for workers

engaged in handling any hot material likely to cause damage to the

hands by burn, scald or scar, or in handling pig iron, rough castings

or other articles likely to cause damage to the hands by cut or

abrasion;

(b) Approved respirators for workers carrying out any operations

creating a heavy dust concentration which cannot be dispelled

quickly and effectively by the existing ventilation arrangements.

(2) No respirator provided for the purposes of sub-paragraph (1) (b) has

been worn by a person shall be worn by another person if it has not

since been thoroughly cleaned and disinfected.

(3) Persons who for any of their time

(a) work at a spout of or attend to, a cupola or furnace in such

circumstances that material there from may come into contact with

the body, being material at such a temperature that its contact with

the body would cause a burn ; or

(b) are engaged in, or in assisting with, the pouring of molten metal; or

(c) carry by hand or move by manual power any ladle or mould

containing molten metal ; or

(d) are engaged in knocking-out operations involving material at such a

temperature that its contact with the body would cause a burn; shall

be provided with suitable footwear and gaiters which worn by them

prevent, so far as reasonably practicable, risk of burns to his feet and

ankles.

(4) Where appropriate, suitable screens shall be provided for protection

against flying materials (including splashes of molten metal and sparks

and chips thrown off in the course of any process).

(5) The occupier shall provide and maintain suitable accommodation for the

storage and make adequate arrangements for cleaning and maintaining

of the protective equipment supplied in pursuance of this paragraph.

(6) Every person shall make full and proper use of the equipment provided

for his protection in pursuance of sub-paragraphs (1) and (4) and shall

without delay report to the Occupier, or other appropriate person any

defect in, or loss of, the same.

(7) Workers working in the furnace/casting pit area shall be provided with

cotton clothes. Safety shoes, leg guards, apron, face shield, hand gloves

and safety helmet.

(8) Workers employed for segregation of scrap shall be provided with safety

shoes and hand gloves.

(9) Five retardant and heat retardant clothing shall be provided to all the

workers working on platform of induction furnace

17. Training and Supervision

(1) All operations under this Schedule shall be carried out under the

supervision of qualified supervisors at all times.

(2) Workers carrying out operations and maintenance activities in foundries

and furnaces shall be adequately trained

18. Washing and bathing facilities

(1) There shall be provided and maintained in clean state and good repair

for the use of all workers employed in the foundry,

(a) A wash place under cover with either

(I) a trough with impervious surface fitted with a waste pipe without plug,

and of sufficient length to allow at least sixty centimeters for every 10

such persons employed at any one time and having a constant supply

of dean water from taps or jets above the trough at intervals of not

more than sixty centimeters ; or

(II) atleast one tap or stand pipe for every ten such persons employed at

any one time, and having a constant supply of dean water, the tap or

stand pipe being spaced not less than 1.2 meters apart ; and

(b) not less than one-half of the total number of washing places

provided under clause (a) shall be in the form of bathrooms ;

(c) a sufficient supply of clean towels made of suitable material changed

daily, with sufficient supply of nail brushes and soap.

(2) The facilities provided for the purposes of sub-paragraph (1) shall be

placed in-charge of a responsible person or persons and maintained in a

clean and orderly condition.

19. Disposal of dross and skimming

Dross and skimming’s removed from molten metal or taken from a furnace

shall be placed forthwith in suitable receptacles.

20. Disposal of waste

Appropriate measures shall be taken for the disposal of all waste products

from shell moulding (including waste burnt sand) as soon as reasonably

practicable after the castings have been knocked-out.

21. Material and equipment left out of doors

All material and equipment left out of doors (including material and

equipment so left only temporarily or occasionally) shall be so arranged

and placed as to avoid unnecessary risk. There shall be safe means of

access to all such material and equipment and, so far reasonably

practicable, such access shall be by roadways or pathways or which shall

be properly maintained. Such roadways or pathways shall have a firm and

even surface and shall, so far as reasonably practicable be kept free from

obstruction.

22. Medical facilities and records of examinations and tests

(1) The occupier of every factory to which the schedule applies, shall

a. employ a Health Surveillance Officer for medical surveillance of the

workers employed therein.

b. provide to the said Health Surveillance Officer all the necessary facilities

for the purpose referred to in clause (a).

(2) Workers employed in this scheduled process / operation shall be medically

examined by the Health Surveillance Officer-

i. Once before employment, to ascertain the physical fitness of the person

to do the particular job:

ii. Once in a period of six months, to ascertain the health status of all the

workers in respect of occupational health hazards to which they are

exposed; and in cases where in the opinion of the Health Surveillance

officer it is necessary to do so at a shorter interval in respect of any

workers.

(3) The pre-employment medical examination shall include pulmonary function

test, and chest X ray.

(4) The periodical re-examination shall, wherever the Health Surveillance

Officer considers appropriate, include all the tests of pre-employment

except the chest X-ray which shall be carried out at least once in three

years.

(5) The record of the examinations referred to in sub-paragraph (2) shall be

maintained in Health Register in Form: XVIII which shall be kept readily

available for inspection by the Inspector-cum-Facilitator.

(6) No person shall be employed for the first time without a Certificate of

Fitness in Form: XVII granted by the Health Surveillance officer. If the

Health Surveillance officer declares a person unfit for being employed in

any process covered under sub-rule (1), such a person shall have the right

to appeal to the Inspector-cum-Facilitator who shall refer the matter to the

Medical Officer whose opinion shall be final in this regard. If the Inspector-

cum-Facilitator is also a Medical Officer, he may dispose of the application

himself.

(7) Any findings of the Health Surveillance officer revealing any abnormality or

unsuitability of any person employed in the process shall immediately be

reported to the Medical Officer who shall in turn, examine the concerned

worker and communicate his findings to the occupier within thirty days. If

the Medical Officer is of the opinion that the workers examined is required

to be taken away from the process for health protection, he will direct the

occupier accordingly, who shall not employ the said worker in the same

process. However, the worker so taken away shall be provided with

alternate placement unless he is in the opinion of the Medical Officer, fully

incapacitated in which case the worker affected shall he suitably

rehabilitated.

(8) A Medical Officer on his own motion or on a reference from an Inspector-

cum-Facilitator may conduct medical examination of a worker to ascertain

the suitability of his employment in the scheduled Process/operation or for

ascertaining his health status. The opinion of the Medical Officer in such a

case shall be final. The fee required for this medical examination shall be

paid by the occupier.

(9) The worker taken away from employment in any process under sub-rule

(2) may be employed again in the same process only after obtaining the

Fitness Certificate from the Medical Officer and after making entries to that

effect in the Health Register.