Schedule 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 moulds

made 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 andthe 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 (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 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 andcores, 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 -

(1) 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 percent 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 fireclay

(d) Sillimanite

(e) Calcined or fused alumina

(f) Olivine

(g) 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 fallowing requirements shall be abserved:-

(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 -

(1) 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.

(2) 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.

(1) 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 andfirm condition.

6. Cleanliness of indoor work places. -

(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 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.]

(2) 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 -

(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, 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 safe means of access from the

floor for any person while engaged in the operation.

8. 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 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;

(c) if not used for carrying molten metal, shall be at least 920 millimetre 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;

(iii) 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.

(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 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 en 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 bul\ 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.

(3) Requirements of sub-paragraph (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 partof a workroom has to be of sand.

(4) ln 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.

9. 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.-

(l) 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 exceptin

circumstances in which the use of such fires is unavoidable.

(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 anyperiod when a person is employed therein.

(4) 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

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 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.

11. Maintenance and examination of exhaust plant -

(1) All ventilation plant used for the purpose of extracting, suppressing or controlling dust

or fumes shall be properly maintained.

(2) All ventilating 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. It shall be

thoroughly examined and tested by a competent person at least once in every such examination

and test shall be entered in a register in FormA2 electronically or otherwise which shall be

available for inspection by an Inspector-cum-Facilitator. Any defect found on any such

examination and carrying out the examination and test to the occupier of the factory.

12. Protective equipment -

(1) The occupier shall provide and maintain protective equipment specified for the

protection of workers,

(a) 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.

(c) No respirator provided for the purposes of clause 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-paragraph (1) and (4) 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 -

(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 !east 60 centimetres for every 10 such persons employed at

any one time and having a constant supply of clean water from taps or jets above the

trough at intervals of not more than 60 centimetres or

(ii) 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 stand pipe being spaced

not less than 1.2 metres apart; and

(b) Not less than one half of the total number of washing places provided under

clause (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.

(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.

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) 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 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 examination by medical officer - (1) every worker employed in the processes

specified in paragraph 1 shall be examined by a Medical officer within15 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.

(2) 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 subparagraph(1).

(3) The Medical officer after examining a worker, shall issue a Certificate of Fitness in

Form-40. 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 occupier of the factory. The

record of each examination carried out under sub-paragraph (1) and (2) including the nature

and the results of these test, shall also be entered by the Medical officer in a health register in

Form-41 electronically or otherwise.

(4) The Certificate of Fitness and the health register shall be kept readily available for

inspection by the Inspector-cum-Facilitator.

(5) 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.

(6) No person who has been found unfit to work as said in sub-paragraph (5) 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 - lf in respect of any factory, the Chief \nspector-cum-Facilitator 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 schedule is not necessary for the protection of the

workers in the factory, the Chief Inspector-cum-Facilitator 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.