Schedule B XXVII

Operations in Foundries

1. Application.—Provisions of this Schedule shall apply to all parts of factories

where any of the following operations or processes are carried on

a. the production of iron castings or, as the case may be, steel castings by

casting in mouldsmade of sand, loam,moulding composition or other

mixture of materials, or by shall 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

of materials, or by shall mouldings, die-casting (including pressure die

casting), centrifugal casting or continuous casting and any process

incidental to such production ; and

c. the melting and casting of non-ferrous metal for the production of ingots,

billets, slabs or other similar products, and the stripping thereof ;

But shall not apply with respect to-

a. Any process with respect to the smelting and manufacture of lead and the

Electric Accumulators ;

b. Any process for the purpose of a printing works; or

c. Any smelting process in which metal is obtained by a reducing operation

or any process incidental to such operation; or

d. The production of steel in the form of ingots; or

e. Any process in the course of the manufacture of solder or any process

incidental to such manufacture; or

f. the smelting 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

a. "approved respirator means a respirator of a type approved by the Chief

Inspector-cum-Facilitator ;

b. "cupola of furnace" includes a receiver associated therewith ;

c. "dressing or fettling operations" includes stripping and other removal of

adherent sand, cores, runners, risers, flash and other surplus metal from

a casting and the production of reasonably clean and smooth surface, but

does not include ;

i. 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

il. Any operation which is knock-out operation within the meaning of this

schedule.

d. "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 shell moulding or by centrifugal casting in metal moulds

lined with sand, or die casting including pressure die casting, together

with any part of the factory in which any of the following processes are

carried on as incidental processes in connection with and in course of,

such production, namely, the preparation and preparation of moulds and

cores, knock out operations and dressing or fettling operations ;

e. "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 ;

f. "pouring aisle" means an aisle leading from a main gangway or directly

from a cupola or furnace to where metal is poured into moulds.

3. Prohibition of use of certain materials as parting materials.-

I. A material shall not be used as a parting material if it is a material

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

5 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 -

a. Zirconium silicate (Zircon) :

b. Calcined china clay :

C.

Calcined aluminous fire clay :

d.

Sillimanite :

e.

Calcined or fused alumina ;

Olivine ;

9.

Natural sand.

Il.

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, loam plates, 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 of floors.-

Floors of indoor workplaces in which the processes are carried on, other than

parts which are of sand, shall have been surface of hard material.

II. No part of the floor of any such indoor workplace shall be of sand except

where this is necessary by reason of the work done.

III. All parts of the surface of the floor of any such indoor workplace which are of

sand shall, so far as practicable, be maintained in an even and firm condition.

6.Cleanliness of indoor workplaces.-

I. 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

metres 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.

IL.

Effective cleaning by a suitable method shall be carried out at least once

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

workplace in which the processes are carried on, other than parts which are

of sand; and the parts which are of sand shall keep in good order.

7. Manual operations involving molten metal.-

I 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 ?

IL

Any operation involving the carrying by hand of a container holding molten

metal shall be performed on a floor all parts of which where any person walks

while engaged in the operation shall be on the same level :

Provided that, where necessary to enable the operation to be performed

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 safemeans of access from the floor for any person

while engaged in the operation.

8.Gangways and pouring aisles.-

L 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 clearly defined main gangway 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;

if not used for carrying molten metal, shall be at least 920 millimetres

in width;

d. if used for carrying molten metal shall be-

i. Where truck ladles are used exclusively, at least 600 millimetres

wider than the overall width of the ladle;

ii. Where hand shanks are carried by not more than two men, at

least 920 millimetres in width;

ill.

Where hand shanks 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 hand shanks, at least 1.8 metres in width.

I1.

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 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 bulk ladles by not more than

two men per ladle, shall be at least 460 millimetres wide, but where

any moulds alongside the aisle are more than 510 millimetres above

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

wide;

d.if molten metal is carried in hand ladles or bull ladles by more than two

men per ladle, shall be at least 760 millimetres 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.

III. Requirements of sub-paragraph (I) and (II) 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.

IV. In this paragraph "workroom 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 workroom 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.

Work near cupolas and furnaces.No person shall carry out any work

within a distance of 4 metres from a vertical line passing through the delivery

end of any spout of a cupola or furnace, being a spout used for delivering

molten metal, or within a distance of 2.4 metres from a vertical line passing

through the nearest part of any ladle which is in position at the end of such a

spout, except, in either case, where it is necessary for the proper use of

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.

10.

Dust and fumes. -

I. 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.

II.

No open coal, coke or wood fires shall be used for drying moulds except in

circumstances in which the use of such fires is unavoidable.

III.

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.

IV. All knock-out operations shall be carried out-

a. in a separate part of foundry suitably partitioned off, being a room or

part in 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 reasonablypracticable, a high

standard of general ventilation is provided.

V. All dressing or fettling operations shall be carried out-

a.

In a separate room or in a separate part of foundry suitably partitioned

off : or

b. In an area of the foundry set apart for the purpose; and shall, so far as

reasonablypracticable, 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.

11. Maintenance and examination of exhaust plant. -

I. Allventilation plant used for the purpose of extracting, suppressing or

controlling dust or fumes shall be properly maintained.

II. All ventilating plant used forthe purpose of extracting, suppressing or

controlling dust or fumes shall be examined and inspected once every week

by a responsible person. It shall be thoroughlyexamined and tested by a

competent person at least once in every such examination and test shall be

entered in an approved register which shall be available for inspection by an

Inspector. Any defect found on any such examination and carrying out the

examination and test to the occupier or manager of the factory.

12. Protective equipment. -

1. The occupier shall provideandmaintain protective equipmentspecified for

the protection of workers-

suitable gloves to 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

have dust concentration which cannot be dispelled quickly and

effectively by the existing ventilation arrangements.

II.

No respirator provided for the purposes mentioned in I (b) has been worn by

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

cleaned and disinfected.

11.

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 therefrom 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 manualpower 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 ;

e. Shall be provided with suitable footwear and gaiters which worn by

them prevent,sofar asreasonablypracticable, risk of burns to his feet

and ankles.

IV. 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).

V. 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.

VI.

Every person shall make full and proper use of the equipment provided for his

protection in pursuance of sub- paragraph (I) and (IV) and shall without delay

report to the occupier, manager, or other appropriate person any defect in, or

less of, the same.

13.

Washing and bathing facilities. -

I. There shall beprovided 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 60

centimetres for every 10 such persons employed at any one

time and havinga constant supply of cleanwater from taps or

jets above the trough at intervals of not more than 60

centimetres; or

il. at least one tap or stand pipe for every 10 such persons

employed at any one time, and having a constant supply of

clean water,the tap or standpipe being spaced not less than

1.2 metres apart; and

Not less than one half of the total number of washing places provided

at (a) shall be in form of bath rooms ;

C.

A sufficient supply of clean towels made of suitable material changed

daily, with sufficient supply of nail, brushes and soap.

Il. The facilities provided for the purposes of sub-paragraph (I) shall be placed in

charge of a responsible person or persons and maintained in a clean and

orderly condition.

14. Disposal of dross and skimming.-Dross and skimming removed from

molten metal or taken from a furnace shall be placed forthwith in suitable

receptacles.

15.

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.

16.

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) shallbe so arranged and placed as to avoid unnecessary risk.

There shall besafemeans of access to all such material and equipment and,

so far as reasonably practicable, such access shall be by roadways or

pathways 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.

17. Medical facilities and records of examinations and tests.-

I. The occupier of every factory to which this Schedule applies, shall-

a. employ a qualified medical practitioner for medical surveillance of the

workers employed therein whose employment shall be subject to the

approval of the Chief Inspector-cum-Facilitator; and

b. Provide to the medical practitioner all the necessary facilities for the

purpose referred to at (a).

The record of such examinations carried out by the medical practitioner shall

be maintained in a separate, register approved by the Chief Inspector-cum-

Facilitator, which shall be kept readily available for inspection by the

Inspector-cum-Facilitator.

18. Medical examination by Medical Officer.-

I every worker employed in the processes specified in paragraph 1 shall be

examined by a Medical Officer within 15 days of his first employment. Such

examinations shall include skin test for dermatitis and no worker shall be

allowed to work after 15 days of his first employment in the factory unless

certified fit for such employment by the Medical Officer.

II.

Every worker employed in a manganese process shall be re-examined by a

Medical Officer at least once in every 12 months and such examination shall,

wherever the Medical Officer considers appropriate, include all the tests in

sub-paragraph (I).

II.

The Medical Officer after examining a worker, shall issue a Certificate of

Fitness in Form XXIII. The record of examination and re-examinations carried

out shall be entered in the Certificate and the Certificate shall be kept in the

custody of the manager of the factory. The record of each examination carried

out under sub-paragraph (I) and (II) including the nature and the results of

these test, shall also be entered by the Medical Officer in a health register in

Form XXIV.

IV.

The Certificate of Fitness and the health register shall be kept readily available

for inspection by the Inspector.

V. If at any time the Medical Officer is of the opinion that a worker is no longer

fit for employment in the said processes on the ground that continuance

therein would involve special danger to the health of the worker, he shall

make a record of his findings in the said certificate and the health register.

The entry of his findings in those documents should also include the period

for which he considers that the said person is unfit to work in the said process

shall be provided with alternate placement facilities unless he is fully

incapacitated in the opinion of the Medical Officer, in which case the person

affected shall be suitably rehabilitated.

VI.

No person who has been found unfit to work as said in sub-paragraph (V)

shall be re-employed or permitted to work in the said processes unless the

Medical Officer, after further examination, again certifies him fit for

employment in those processes.

19.

Exemptions.-If in respect of any factory, the Chief Inspector is satisfied

that owing to the exceptional circumstances or infrequency of the processes

or for any other reason, all or any of the provisions of this Part is not

necessary for the protection of the workers in the factory, the Chief Inspector

may be a certificate in writing which he may in his discretion revoke at any

time, exempt such factory from all or any of such provisions subject to such

conditions, if any, as he may specify therein.