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 castings in

molds made of sand, loam, molding composition or other mixture of materials, or

by shell molding, or by centrifugal casting and any process incidental to such

production;

(b) the production of non-ferrous castings by casting metal in molds made of sand,

loam, metal, molding composition or other material or mixture of materials or by

shell moldings, die- casting (including pressure die-casting), centrifugal casting of

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,-

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

Electric Accumulators;

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

(iii) any smelting process in which metal is obtained by a reducing operation or

any process incidental to such operation; or

(iv) the production of steel in the form of ingots; or

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

incidental to such manufacture; or

(vi) The melting and casting of lead or and 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. Definitions.- For the purpose of this schedule,-

(a) "approved respirators" means a respirator of a type approved by the Chief

Inspector-cum-Facilitator;

(b) "cupola or 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

(ii) any operation which is a 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 molds made of sand, loam,

molding composition or other mixture of materials, or by shall molding or by

centrifugal casting in metal molds 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 the course of such production namely the preparation and mixing of materials

used in foundry process the preparation of molds and cores, knock out operations

and dressing or fettling operation;

(e) "knock-out operations" means all methods of removing casting from molds and

the following operations, when done in connection therewith namely, stripping,

coring out and the removal of runners and risers; and

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

cupola or furnace to where metal is poured into molds.

‍573

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 fire clay

(d) Sillimanite

(e) Calcined or fuses alumina

(f) Olivine

(g) Natural sand

(2) Dust or other matter deposited from a fettling or blasting processes 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 requirement shall be observed:-

(a) molding 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; and

(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 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 or 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 workplace which are of sand shall,

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

6. 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 meter 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 clause including the date (which shall be not less

than five months or 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 one other than parts which are of sand: and the parts which are of sand shall be kept 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 clause 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 work-room to which this clause applies

constructed, reconstructed or converted for use as such after the making of this schedule and,

so far as reasonably practicable, in every other work-room to which this clause applies,

sufficient and clearly defined main/gangways shall be provided and properly maintained

which:—

(a) shall have as 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 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 or 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 metres 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 clause 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,-

‍575

(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 at least 460 millimetres wide, but where any molds alongside

the aisle are more than 510 millimetres above the floor of the aisle. The aisle shall

not be 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 the width

adequate for the safe performance of the work.

(3) Requirements of sub-clause (1) and (2) shall not apply to any workroom or part of a

workman if, by reason of the nature of the work done therein, the floor of that work-room or,

as the case may be, that part of a work room has to be of sand.

(4) In this clause "workroom to which this clause 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

clause applies shall be deemed for the purposes of this clause 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 lines 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.- (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 molds except in circumstances

in which the use of such fires is unavoidable.

(3) Mold stoves. core stoves and annealing furnace 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 part in

which, so far as reasonably practicable, affective and suitably 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 a part 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 plants used for the

purpose of extorting, suppressing or controlling dust or fumes shall be properly maintained.

(2) All ventilating plants used for the purpose of extracting, sup-pressing 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 period of

twelve months, and particulars of the results of every such examination and test shall be

entered in an approved register which shall be 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 or manager of

the factory.

12. 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 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 therefore 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

‍577

(c) carry by hand or move by manual power any ladle or mold 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 the 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 clause.

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

in pursuance of sub-clause (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. Disposal of dross and skimming.- Dross and skimming removed from molten metal or

taken from a furnace shall be placed forthwith in suitable receptacles.

14. Disposal of Waste.- Appropriate measures shall be taken for the disposal of all waste

products from shell molding (including waste burnt sand) as soon as reasonably practicable

after the castings have been knocked out.

15. 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.

16. Medical Examination.- Every worker employed in a foundry shall be examined by a

Medical Officer within 15 days of his first employment, such medical examination shall

include pulmonary function tests and chest X-ray.

17. Exemption.- If in respect of any factory, the Chief Inspector-cum-Facilitator is satisfied

that owing to the exceptional circumstances or in frequency of the processes or for any other

reason, all or any of the provisions at this schedule is not necessary for protection of the

workers in the factory, the Chief Inspector-cum-Facilitator may by a certificate in writing,

which be may at 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.